NextGeneration of Battery Management Systems to increase Interoperability, bridge the Gap between 1st and SL-BESS, Extend Adaptability and emPower battery value chains.

Project Information

BIG LEAP

Grant agreement ID: 101137815

DOI

10.3030/101137815

EC signature date 8 December 2023

Start date 1 January 2024

End date 30 June 2027

Funded under

• Climate, Energy and Mobility

Total cost

No data

EU contribution

€ 7 024 569,74

Coordinated by

BRUSSELS RESEARCH AND INNOVATION CENTER FOR GREEN TECHNOLOGIES
Belgium

Periodic Reporting for period 1 - BIG LEAP (NextGeneration of Battery Management Systems to increase Interoperability, bridge the Gap between 1st and SL-BESS, Extend Adaptability and emPower battery value chains.)

Reporting period: 2024-01-01 to 2025-06-30

Summary of the context and overall objectives of the project

BIG LEAP addresses a critical challenge in the transition to clean energy: the lack of interoperability and standardisation in BMS and ESS, which hinders the efficient and cost-effective repurposing of First-Life Batteries (FLB) into Second-Life Battery Energy Storage Systems (SL-BESS). Currently, adapting FLBs for stationary applications involves time-consuming, expensive, and highly customised processes due to differences in battery designs, chemistries, and state-of-health profiles. These limitations reduce the economic viability of SL-BESS, slow their market adoption, and restrict their potential to contribute to decarbonisation and resource efficiency goals.

To overcome these barriers, BIG LEAP will design, develop, and validate an innovative three-layer BMS and interoperable ESS architecture capable of managing multiple battery chemistries and configurations across first- and second-life applications. The project will integrate advanced features such as Probabilistic Data Association (PDA) for chemistry identification, in-site end-of-life (EoL) diagnostics, adaptive SoX algorithms, impedance-based diagnostics, and Digital Twin models for real-time monitoring and predictive maintenance. By combining hardware adaptability, low-level software control, and cloud-based intelligence, the project aims to ensure safe, reliable, and updatable BESS operation while significantly reducing refurbishment costs and extending battery lifetimes.

The pathway to impact is underpinned by three demonstration sites, that will validate the technical solutions in real and simulated environments. These will be complemented by a standardisation roadmap, a Digital Battery Passport (DBP) alignment framework, and comprehensive environmental, economic , and social impact assessments. Through its innovations, BIG LEAP seeks to accelerate the uptake of qualified SL-BESS, reduce the need for new raw materials, and strengthen the European battery value chain. In the medium-to-long term, the project is expected to deliver measurable benefits, including reduced greenhouse gas emissions, extended battery lifespans, lower costs for energy storage deployment, and the establishment of industry standards that enable large-scale, sustainable battery reuse.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

During RP1, the project defined FL/SL-BESS use cases and interoperability requirements across hardware, low-level software, and cloud-based software layers, establishing a comprehensive KPI matrix. Dismantling studies were performed, and an internal battery delivery plan was created in alignment with demo timelines. The team designed a range of interoperable BMS topologies covering multiple chemistries and applications and developed failsafe operation strategies, including a PDA method for chemistry identification, impedance-based diagnostics, an enhanced decision unit, cell balancing circuitry, and an optimal charging algorithm. Modular ESS cabinet concepts were completed for multiple module types and demo configurations. In parallel, SoX (SoC, SoE, SoH, SoP, SoS) and RUL (RU1L, RU2L) algorithms were specified, developed, and validated with high accuracy (SoX/SoH MAPE ~3%), and chemistry-specific ECMs for NMC, LFP, LCO, and NCA were created for Digital Twin integration. Battery data requirements were identified and standardized, the initial cloud-based infrastructure for algorithm hosting, data processing, and visualisation was deployed, and progress was made on predictive maintenance and fault detection capabilities. Furthermore, the initial standardisation framework for multi-operational BMS and DBP alignment was defined, LCA, CBA, and social assessment system boundaries were established, baseline and BigLeap scenario modelling was initiated, and the business case methodology was launched.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

BIG LEAP is advancing the state of the art in SLB technology through the design and validation of an interoperable, three-layer BMS and modular ESS architecture. The system integrates advanced SoX and RUL algorithms (error rate ~3%), chemistry-agnostic control strategies, and DT models for predictive diagnostics and optimised reconfiguration. Modular cabinet designs, BPUs, and reconfiguration tools have been developed to reduce dismantling complexity and enable compatibility with diverse chemistries. Initial standardisation and DBP frameworks are in place, alongside baseline environmental , economic, and social assessments.

The expected impacts include:

Technical: 30–57% reduction in SLB repurposing costs, 25% faster qualification strategies, 40% shorter manufacturing times, and significant improvements in safety and lifespan through precise SoX estimation.

Economic: Creation of new markets for interoperable SL-BESS, cost savings exceeding €190k/MWh over 10 years, and the generation of new jobs in collection, dismantling, and reassembly phases.

Environmental: Reduction of up to 1,906 tCO2/MWh over 10 years, extended battery lifetimes by at least a decade, and measurable resource savings (250 t mineral ore and 1,900 t water per tonne of SL Li-ion battery).