Risk and condition informed decision support framework for end-of-life management of batteries

Efficient management of end-of-life lithium-ion batteries (LIBs) is critical to advancing circular economy goals. To support informed decision-making for circular strategies (ReX) such as reuse, remanufacturing, repair, or recycling, this study proposes a systematic and adaptive framework D-BReX (Decision-Making Framework for Circularity and Assessment of ReX in Battery Life Cycles). The framework is designed to leverage structured data from the Digital Battery Passport (DBP) and integrates it with fuzzy Failure Mode and Effects Analysis (FMEA) and State of Health (SOH) assessments. This hybrid approach allows for risk- and condition-based evaluation at the pack, module, and cell levels, supporting scalable, safety-conscious ReX decisions. The framework includes cost modelling to quantify trade-offs between diagnostic thoroughness and operational efficiency. A case study on retired E-bike battery packs demonstrates how D-BReX adapts to varying failure profiles and supports optimal ReX strategies under different economic and safety constraints. The findings affirm that D-BReX is effective in guiding second-life battery decisions, offering a structured yet flexible approach aligned with circular economy (CE) goals. Its iterative structure also enables continuous enhancement of DBP data, improving traceability and long-term decision quality.