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encore – extending battery life

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encore – extending battery life

Old battery. New energy storage system. encore.

encore [ˈɑ:nkɔ:r] from English: "encore, bonus", from French: "once again“

Lithium-ion batteries are considered a key technology in electric mobility, yet they lose storage capacity over the course of their lifetime. After eight to ten years, the battery's performance drops to below 80 per cent and is therefore often replaced.

We take used batteries from manufacturers and authorised dealers of e-vehicles across Europe and use them to produce modular second life battery energy storage systems. Batteries whose performance is no longer sufficient for a second life are sorted out and passed on for professional recycling.

The second life of a battery not only improves the CO2e footprint of electric mobility, but it also supports the decarbonisation of energy by providing sustainable battery energy storage systems, which are particularly needed in times of volatile renewable energy. This very idea was the starting point of our journey at Deutsche Bahn (DB) in 2019. As Germany's largest logistics and mobility service provider, DB is on one hand increasingly relying on batteries as an alternative propulsion technology in its own vehicles (trains, trucks, passenger cars), and on the other hand is upgrading its own infrastructure to incorporate more renewable energies to achieve climate neutrality by 2038, which are ideally complemented by second life battery energy storage systems.

What we do

01 Manufacturers of electric vehicles replace the battery after approx. 8-10 years. The battery packs are picked up directly from the workshop.

02 The battery pack is transported by road or rail via the Deutsche Bahn logistics network to second life processing.

03 The battery pack is dismantled into individual battery modules and the remaining raw materials are recycled or reused.

04 The battery modules are subjected to a safety and quality analysis. They are also analysed for their remaining capacity.

05 Battery modules with sufficient remaining capacity are reused to produce encore second life battery energy storage systems.

06 In their second life, the battery energy storage systems can be used, for example, for storing PV energy, peak shaving, an uninterruptible power supply, stabilising grids, and/or buffering electric vehicle charging points.

07 Battery modules that are unsuitable for a second life are sent to be professionally recycled.

08 The recovered materials are used for the production of new battery cells.

Zitat

It's more urgent than ever for us to save power. Our new second life battery energy storage systems offer a solution that is also sustainable. And that makes it an attractive option for any industry.

Berthold Huber

Member of the Management Board of Deutsche Bahn for Infrastructure

Safe. Sustainable. Profitable.

Every battery module that is installed in our second life battery energy storage systems is subjected to intensive testing. In this way, we ensure that only battery modules that meet the highest standards of safety, quality and performance are used.

By using raw materials that are already in circulation, our second life battery energy storage systems are more sustainable than battery energy storages with new battery modules. By using second life battery energy storage systems, we can save 6 tons of CO2 emissions in the production of a 65-kWh battery storage in direct comparison with new battery energy storage systems.

Our second life battery energy storage systems are more financially economical when compared to battery energy storage systems made with new battery modules - an important advantage for our customers. The modular design also offers a high degree of flexibility for different application possibilities and sizes in the profession. This means that the energy storage systems can be individually adapted to the respective needs and can also be expanded later.

Use cases

Self-consumption optimisation

Second life battery energy storage systems can help to increase the self-consumption of electricity produced from solar PV or wind turbine assets, thus increasing the degree of self-sufficiency and ultimately the economic viability of renewable energy systems.

Peak shaving

A load peak is a very high demand for electricity for a short period of time, which determines part of the electricity price to be paid. Second life battery energy storage systems can reduce these electricity costs by providing the required electricity from the battery energy storage system rather than drawing it from the public power grid.

Power supply

In the event of unplanned, short-term power failures, second life battery energy storage systems ensure that electrical components are constantly supplied with power.

Grid stabilisation

Second life battery energy storage systems are used to stabilize the grid when there is too much or too little electricity being fed into the grid at short notice. They can also help to prevent local grid bottlenecks and thus avoid expensive grid expansion investments.

Buffered charging

Electric vehicle charging points combined with second life battery energy storage systems ensure that several electric vehicles can be charged in parallel without overloading the local power grid.

Partners

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Enabled by

As a corporate start-up made up of energy storage specialists, encore is part of the DB Bahnbau Group. encore brings together the network, expertise, and experience in the development of alternative energy systems from the wider DB groups and partners.

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Powered by

The Korean car manufacturer Kia provides encore with used batteries from all over Europe with the aim of giving as many as possible a second life as battery energy storage systems.

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Dismantled by

The specialist company from Hockenheim is responsible for the dismantling of the battery packs and subjects them to an AI-based safety and quality analysis, thus determining the remaining capacity and expected service life of the battery modules for second-life applications

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Electrified by

With their innovative inverters with integrated battery management system, the Munich-based start-up STABL Energy makes it possible for us to combine different battery modules with varying state of health and allow continued operation, even if a battery fails.

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Managed by

The joint venture of DB E.C.O. and Schneider Electric provides the basis for the first pilot of our second life battery energy storage system at the EUREF-Campus in Berlin by operating the Micro Smart Grid and by providing the premises including the energy management system.

Transported by

DB Schenker is responsible for the Europe-wide logistics of the used battery packs by land, while DB Cargo transports them by rail.

Team

Ilma Bojadzic
Strategy & Partnership
Encore (1 von 10)
Fabian Cordes
Business Model & Customer Development
Encore (6 von 10)
Philipp Freisler
Production & Logistics
Encore (8 von 10)
Lucas Weidner
Product Development
Encore (1 von 1)
Pierre Amend
Product Development
Thomas Franks
Product Development
Roman Wangelow
Product Development
Sebastian Günther
Product Development
Tigran Tonoyan
Strategy
Linda Segerer
Sustainability & Circular Economy
Antonia Hacker
Marketing

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