This technical note provides comprehensive guidance on how to ensure responsible and safe handling of these batteries throughout their life cycle, from their use in electric vehicles to their "second life" reuse or final recycling.

Why is safe battery management important?

The electric vehicle (EV) market is booming. Each battery can operate efficiently for 6-8 years, but after that, even if they lose some of their capacity, they still have value for stationary or lower demand applications. Without proper management, batteries could become an environmental and safety challenge, in addition to requiring continuous extraction of critical materials such as lithium, nickel and cobalt.

Key risks to consider

High-voltage (HV) batteries introduce electrical, thermal and chemical hazards that do not exist in conventional vehicles. Electrical discharges, arcing faults, overheating and thermal runaway are frequent risks if proper protocols are not followed. (thermal runaway) are frequent risks if proper protocols are not followed. In addition, during disassembly or transport, batteries require additional measures to protect both workers and infrastructure.

Four pillars for secure management

International experience shows that security is based on four essential components:

1. Specialized infrastructure: Storage areas with fireproof materials, adequate ventilation, thermal detection systems and alarms connected to first responders. In vehicles, the arrangement in "islands" of no more than four units is recommended to reduce risks.
2. Protective equipment and tools (PPE): Insulating gloves, face shields, helmets, dielectric footwear and tools with specific insulation. Thermal imaging cameras and monitoring systems are key allies in incident prevention.
   

1. Clear internal protocols: From safe disconnection of the electrical system to verification of absence of voltage, following regulations such as DGUV 209-093 (Germany) and Royal Decree 614/2001 (Spain). These regulations define five basic safety rules: disconnection, securing against reconnection, voltage verification, earthing (where applicable) and protection against live parts.
2. Continuous training: Training of personnel is mandatory. Levels range from basic awareness (driving and minor tasks) to advanced training for handling high voltage systems. The latter includes more than 100 hours of theoretical and practical training, first aid and periodic revalidations.

Second life and recycling

Before recycling, many batteries have the potential for a second life in stationary storage systems, as energy backup for power grids or industrial facilities. However, disassembly or handling of these systems requires clear identification of high voltage (HV) components, which are often marked with orange wires and warning signs.

Recycling, on the other hand, involves the recovery of valuable metals and the minimization of hazardous waste. To do this, the battery must be deactivated by qualified personnel and managed in facilities designed to contain any electrical or chemical hazards.

International lessons and transition to the circular economy

Countries such as Germany and Spain already have advanced regulatory frameworks. This technical note highlights the importance for Latin America to develop local regulations and standards that include the certification of specialized workshops and technicians. Early adoption of these frameworks can strengthen the transition to a circular economy, reducing pressure on natural resources and promoting more sustainable industries.

To learn more about these recommendations and to learn more about specific cases, you can download the complete technical note in this link.