Earlier this year, we caught up with Tania Saxby, Head of Sustainability at Connected Energy to delve into the company’s innovative approach to enhancing the circular economy by repurposing electric vehicle (EV) batteries.
Connected Energy was founded in 2010 to solve two main environmental challenges:

• Creating reliable storage or renewable energy generation
• Finding a second life for EV batteries

With increasing demand for EVs (in the UK, 2024 was a record breaking year with a 2.6% increase in the sale of new EV cars to 1.95m), the opportunity to move towards cleaner transportation methods appears, but so does the challenge of what to do with the lithium-ion batteries used in these vehicles as they come to the end of their life cycle.

Currently, the battery life of an EV is 10-15 years before they begin to drop in range, becoming unsuitable for further use in transport. However, these batteries still have a capacity of 80-85%. Enter Connected Energy. Offering an alternative that prevents EV batteries going directly to landfill, or directly through the costly process of recycling, Connected Energy focus on “repurposing before recycling”. They take end of life EV batteries and repurpose them in their energy storage systems, increasing the life of the battery by about 10 years.

Connected Energy’s Circular Model for EV batteries:

The Connected Energy ‘E-STOR’ battery energy storage systems are then used to store excess energy generated by renewables, allowing for a consistent supply even when the sun isn’t shining, or the wind isn’t blowing. Businesses using renewable energy generation are then able to better manage this energy, integrating the system with energy assets on site and supporting energy optimisation.

But it’s not just storage on offer. Connected Energy have designed cloud-based energy management software which automates and optimises the use of the battery energy storage system in real-time. It allows the system to be charged and discharged to complement your site’s operations, responding to multiple parameters on-site or off-site according to a pre-set hierarchy of priorities.

Connected Energy’s Journey

Connected Energy’s journey in the Hethel Innovation network has been impressive. Starting off in a small office at Hethel Engineering Centre in 2017 with a headcount of 7 people, they proceeded to double in size, growing into one of our large offices. In 2021 they took on 4 workshops with mezzanines, consolidating their office and workshop space into a single space, allowing them to take their R&D in-house.

The Hethel Innovation team has been there to support every step of the way, taking a flexible approach to the tenancy offer to support Connected Energy’s growth, as well as delivering support directly to the team working on site including agile project management workshops, and support to identify and access grant funding. The company is now looking to expand even further on a different Hethel Innovation-run site.

We’re thrilled to see how the company has grown over the last several years. Connected Energy are in a really exciting stage of their growth, and we can’t wait to see what’s next for them.

Check out Tania’s interview where she details

What You’ll Learn:

Repurposing EV Batteries: Discover how Connect Energy extends the life of EV batteries, which still hold about 80% capacity after their initial use in vehicles. By repurposing these batteries for energy storage, they can significantly increase their lifespan and reduce waste.

Environmental Benefits: Learn about the positive impact of their battery energy storage systems on the transition to renewable energy. They capture excess energy generated from renewable sources and store it for use when conditions aren’t optimal.

Company Growth Journey: Tanya discusses Connected Energy’s evolution from a small innovation project with Lotus to its current operations at Hethel Engineering Centre, where they now have multiple workshops and exciting plans for expansion.

Data-Driven Insights: Explore how the data services team provides customers with valuable insights into battery performance, helping them achieve their economic and environmental goals through customizable control schedules.

Supporting the Circular Economy: Find out how they work closely with EV manufacturers to help them manage end-of-life batteries, avoiding costly recycling processes while retaining ownership of valuable materials.

Future Aspirations: Get a sneak peek into plans for developing larger systems that utilize second-life EV batteries and how they are collaborating with Hethel Innovation to find suitable sites for growth.

She highlights the significant financial and environmental challenges associated with recycling EV batteries, noting that current recycling costs can reach approximately £2,000 per battery and involve carbon-intensive processes.

To address these issues, Connected Energy offers a solution that maximizes the usable life of EV batteries. By integrating used batteries into their energy storage systems, manufacturers can extend battery life, generate additional revenue, and retain ownership of valuable materials for future recycling. This approach not only reduces waste but also supports a more sustainable and cost-effective supply chain.

Saxby emphasizes the importance of collaboration within the industry to create models for true battery circularity, ensuring that resources are utilised efficiently and responsibly throughout the battery lifecycle.

For a more in-depth understanding, you can watch the full video below: