Comparative Performance of New and Remanufactured Lithium-Ion EV Battery Packs in Ghana

Abstract

Background: The rapid transition toward electric mobility has increased the demand for lithium-ion electric vehicle (EV) batteries; however, the high cost of new battery packs remains a major barrier to EV adoption in developing countries such as Ghana. This study comparatively assessed the real-world performance of new and remanufactured lithium-ion EV battery packs under Ghanaian driving and environmental conditions through practical road testing. Objective: The study aims to evaluate and compare the technical and environmental viability of using remanufactured lithium-ion batteries as a sustainable alternative to new or degraded batteries for electric vehicles in Ghana. Method: An experimental comparative research design was employed using a converted electric vehicle fitted alternately with a new battery pack and a remanufactured battery pack. The batteries were evaluated under morning, afternoon, and evening driving scenarios across level roads, hilly terrains, highways, and traffic-congested conditions. Key performance indicators assessed included state of charge (SOC), battery percentage drop, charging efficiency, internal resistance, thermal performance, voltage stability, and driving range. Results: The results showed that the new battery exhibited superior overall performance compared to the remanufactured battery. Internal resistance measurements revealed that the new battery recorded lower resistance values of 20 mΩ at the cell level and 22 mΩ at the module level, whereas the remanufactured battery recorded higher values of 35 mΩ and 41 mΩ, respectively, indicating increased energy losses and degradation tendencies in the remanufactured system. The charging analysis further demonstrated that the new battery reached 100% SOC within 90 minutes using a 60 kW DC fast charger, while the remanufactured battery required 120 minutes under similar charging conditions. Road test results indicated a strong negative correlation between travel distance and battery percentage for both battery systems across all test periods. During the morning test, the Pearson correlation coefficients were for the new battery and for the remanufactured battery, with p-values less than 0.0001, confirming statistically significant discharge behavior. Similar trends were observed during the afternoon ( and ) and evening ( and ) sessions. The average battery percentage drop across all operational periods was higher for the new battery (186.99%) than the remanufactured battery (173.33%), with performance differences increasing progressively from morning (2%), afternoon (4%), to evening (7.33%) conditions. Conclusion: The findings demonstrate that although remanufactured lithium-ion batteries exhibit moderate reductions in efficiency, thermal stability, and energy retention compared to new batteries, they still maintain acceptable operational performance for short-distance and urban EV applications. The study concludes that remanufactured EV batteries can provide a cost-effective and environmentally sustainable alternative for electric mobility deployment in Ghana, particularly within commercial transportation and circular economy frameworks.