Contributed by Max Khabur, director of marketing at Bluewater Battery Logistics

As renewable energy generation continues to grow, the use of battery energy storage systems (BESS) in solar farms has become increasingly important for stabilizing the grid and enabling the integration of intermittent solar and wind power. The permitting process to build a BESS facility often requires a formal plan for site decommissioning and disposal, even if this won’t happen for many years. When a BESS does reach the end of its useful life, disposal can be a complex task that must be carefully planned and executed. 

If you are just starting the permitting process, or in the early stages of BESS project development, this article is for you!  

Brian Davenport, vice president of energy at Industrial Process Design, reminds us of Benjamin Franklin’s famous quote: “By failing to prepare, you are preparing to fail”. 

Decommissioning a BESS facility is a multi-step process that requires careful planning and coordination. Prior to the start of work, the appropriate disposition for all materials must be defined. The goal is to maximize reuse and repurposing wherever possible and recycling in full compliance with the local safety and environmental regulations, while properly disposing of any hazardous or non-recyclable components. With a disposition plan in place, and leveraging their practical knowledge and experience, Brian and his colleague Steve Feinberg, President at Bluewater Battery Logistics, break down the process into five key steps: 

Successful BESS decommissioning requires meticulous planning and coordination of logistics.

Decommissioning BESS poses significant safety risks, including electrical hazards, fire and explosion risks, and exposure to hazardous materials. A comprehensive safety plan is essential, with proper training, personal protective equipment, and procedures in place to mitigate these risks.

Developing an accurate scope of work and associated fees is critical, as BESS decommissioning can be a complex and costly endeavor. The presentation provides a sample fee breakdown for a 120 MW BESS site, which estimates $1.4 million for decommissioning and demolition, and an additional $4.6 million for material disposition. 

Carefully planning the rigging and transportation logistics is crucial. This includes determining the number and size of picks required, the need for specialized equipment like crawler cranes, and the number and type of trucks needed for material removal and transport. Access constraints and site conditions must also be considered. 

BESS decommissioning must comply with all relevant regulations and requirements set forth by the Authority Having Jurisdiction (AHJ). These can vary significantly from state to BESS decommissioning must comply with all relevant regulations and requirements set forth by the Authority Having Jurisdiction (AHJ). These can vary significantly from state to state (and from site to site), so a thorough understanding of local rules and regulations is essential. 

One of the most critical aspects of BESS decommissioning is the proper disposition of the various components. The presentation emphasizes the importance of exploring all options for reuse, recycling, repurposing, and resale, to minimize waste and maximize the value of the recovered materials. 

The battery modules are the most valuable and complex component. Their disposition is heavily influenced by battery chemistry, with NMC batteries typically having a higher recycling value compared to LFP batteries, which may often incur a recycling charge. The battery’s condition and intensity of use in its first-life application also play a significant role in determining whether you recycle of repurpose the batteries. 

In addition to the battery modules, other BESS components such as enclosures, switchgear, transformers, power conversion systems (PCS), and cabling/conduit can also be reused, recycled, or repurposed. Careful planning is required to ensure these materials are handled and transported safely. 

BESS decommissioning often involves unexpected challenges, equipment failures (e.g., pneumatic bander) or the need for improvised solutions (e.g., using a car inverter to charge power tools). Having a backup plan for every step of the process is essential. 

The sheer number of components involved, from screws to bus connections, requires meticulous attention to detail. Verifying critical dimensions, anchor points, and container heights is crucial to ensuring a smooth decommissioning process. 

Proper packaging and labeling of batteries, especially hazardous waste like damaged battery modules, is required for safe transportation. Coordinating with recyclers and ensuring they are equipped to handle the materials is also a key consideration. 

Each BESS site is unique, with its own set of access constraints, traffic flow patterns, and other site-specific requirements. Developing a comprehensive understanding of the site conditions is necessary to plan and execute the decommissioning effectively. 

As the adoption of renewable energy and BESS technologies continues to grow, the need for comprehensive decommissioning and end-of-life planning will only become more critical. IPD and Bluewater Battery Logistics have developed deep expertise in the field and can help navigate the complexities and challenges involved in this process. Preparation, attention to safety, and a holistic approach to utilizing batteries at various stages of their life cycle contribute to the circular economy. Reusing batteries, rather than recycling them, maximizes battery value, and minimizes environmental impact. 

By learning from the experiences and lessons shared, BESS owners and operators can better anticipate and navigate the decommissioning process, ensuring a safe, efficient, and environmentally responsible outcome. 

Max Khabur is a director of marketing at Bluewater Battery Logistics, one of the leading U.S. operators in the second-life battery market. Formerly Max led marketing at OneCharge Lithium Batteries and was elected Chairman of the Advanced Energy Council, representing a group of companies – members of the MHI.org (Materials Handling Industry) Association.