Electric vehicles (EVs) are gaining importance over internal combustion engine (ICE) vehicles to curb carbon emissions caused by the transportation sector. Globally, the share of electric light-duty vehicle sales increased from 9 % in 2021 to 14 % in 2022, and an estimated 18 % in 2023, with China leading the market. The penetration of EVs in emerging markets like China and India is led by 2- and 3-wheelers, predominantly. Currently, almost all the EVs are powered by lithium-ion (Li-ion) batteries owing to favourable performance parameters. But, EVs’ wide penetration is challenged for two key reasons. First, the scarce availability of essential raw materials like lithium, and cobalt. Secondly, thermal hazard posed by Li-ion batteries is a matter of concern, specifically in countries where the ambient temperature is higher. To overcome these problems, we have developed zinc-air batteries which are completely safe and cheap due to abundantly available raw materials. We have decoupled charging and discharging processes and operated them simultaneously. A zinc charging station was built to recycle discharged zinc oxide from battery using renewable energy, and stored safely as compact zinc plates for more than a year with negligible self-discharge. This enabled excess renewable energy storage as and when it is generated. A mechanically refuellable zinc-air single cell was designed and fabricated with our proprietary in-house developed gas diffusion electrodes. The recycled compact zinc plates can be inserted in the battery pack for discharge upon energy demand in EVs.