Longevity of lithium-ion batteries in EV applications: techno-economic and environmental impact considerations toward sustainability

With the rapid expansion of electric vehicle (EV) adoption, increasing concerns over battery degradation, rising material costs, and new policies promoting second-life applications are driving the demand for extended lithium-ion battery (LIB) longevity. This review explores strategies to enhance the longevity of LIBs, focusing on both technological innovations and sustainability aspects crucial for their application in EVs. While prior reviews focused only on individual factors such as heat control or material degradation, this work integrates perspectives across battery longevity, health monitoring, degradation mechanism, reuse and recycling, thermal management design, environmental impact, and techno-economic feasibility. It presents a comprehensive analysis of material innovations, design strategies, and thermal management systems that can significantly extend battery lifespan. Special attention is given to the role of battery thermal management systems (BMS) in reducing degradation and optimizing performance under various environmental conditions. The review further investigates the environmental impact of LIBs, emphasizing life cycle assessments (LCA), carbon footprints, and resource consumption in battery production and recycling. Key strategies for battery longevity include active and passive cooling systems, state-of-charge management, and thermal stress management, along with the reuse, repurposing, and recycling of LIBs. Moreover, it provides an economic evaluation of these technologies, considering the cost implications for EV adoption and the long-term benefits of improved battery lifespan. Through modeling battery performance and comparing different designs, the review offers insights into the techno-economic challenges and opportunities in scaling longevity-focused approaches. Finally, it discusses the future directions for overcoming technical and policy-related challenges, recommending pathways toward a circular economy that will enhance the sustainability of LIBs in EVs.