Porsche has repurposed around 4,400 used Taycan battery modules to create a stationary energy storage system that powers its Leipzig plant, demonstrating the “Second Life” concept for high-voltage electric vehicle (EV) batteries. This system, covering an area nearly the size of two basketball courts, utilizes batteries from pre-series and test vehicles.
The initiative, developed by Porsche’s Environmental and Energy Management unit, underscores how used EV batteries can be effectively reused to conserve resources and extend their lifecycle. According to Porsche, the project provides valuable insights into how automotive plants can be supplied with energy intelligently, while also supporting the expansion of adaptable power grids.
“This project isn’t just about addressing environmental concerns or energy supply,” said Alwin Schmid, Porsche’s Head of Electrical Engineering and the project initiator. “It was also important for us to pioneer the use of this storage system.” Schmid initiated the project following a feasibility study in collaboration with the University of Applied Sciences Zwickau.
Schmid highlighted that the project successfully combined several objectives, including peak load capping, optimizing self-consumption, and participating in the energy market simultaneously.
Albrecht Reimold, Porsche AG’s Executive Board Member for Production and Logistics, emphasized the project’s significance in promoting sustainable resource use while maintaining business efficiency. He added that insights from this project could lead to similar implementations at other Porsche sites.
The battery storage system at the Leipzig plant has a capacity of five megawatts and an energy content of 10 megawatt-hours. It can operate at up to 20% overload for short periods and consists of 4,400 individual battery modules divided into four containers. Each battery string is connected to an inverter and a transformer within a medium-voltage system.
Designed for a lifespan of more than 10 years, the system allows for the replacement of individual battery modules if necessary. The electricity for this storage system is partially generated by the plant’s solar panels, which have a peak output of 9.4 megawatts, helping to reduce peak loads.
Porsche also noted the importance of rapidly controllable energy storage systems like the one at the Leipzig plant in the energy market. “By the end of the year, the stationary battery storage system will be integrated into the balancing energy market in all marketable forms,” Porsche stated. This includes roles beyond peak shaving, such as grid stabilization for upstream distribution networks.
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