The growth in demand for electric vehicles (EVs) is driven by several factors, including the government strategies to promote sustainability, growing consumer awareness of environmental issues and technological advances. However, the high economic and environmental cost of producing lithium-ion batteries remains a problem to be solved, so optimising the manufacture and disposal of their components is key to the further development of this technology.
Optimisation of production processes for batteries for electric cars
Batteries are estimated to be responsible for as much as 40-50% of electric vehicle emissions and account for a similar percentage of their price. That is why electric car battery manufacturers are looking for ways to reduce the cost of production while reducing their carbon footprint. An important aspect is the reduction in human labour, thanks to the increasing automation of production lines. Robots can perform repetitive and precise tasks faster and more efficiently than humans, leading to an overall reduction in costs. For example, they can assemble cells, coat electrodes and test batteries.
Automation also reduces the possibility of any deviations affecting product quality and safety. However, not all companies can afford this, which is why it can also be extremely valuable to forge strategic partnerships with technology and raw material suppliers providing greater access to innovative solutions.
However, the optimisation of production processes is expected to lead not only to a reduction in financial outlay, but also in environmental costs. It can involve, for example, the use of renewable energy sources in factories, such as solar, wind or geothermal energy. This results not only in a reduced carbon footprint, but also lower operating costs. Many battery manufacturers nowadays are investing in PV systems, for example. It is also a rational choice to use components manufactured using modern technologies that consume less energy and have lower emissions. For example, instead of the energy-intensive production of metal battery cases for an electric car, moulded polypropylene EPP components can be used, which are produced in a sustainable process using steam.
Battery recycling and the closed-loop economy
In the context of battery production cost and the carbon footprint of the automotive industry, the importance of a circular approach based on the effective recycling of materials from used batteries has increased. Currently, various methods are used to recover lithium, nickel and cobalt, such as pyrometallurgy, hydrometallurgy or physico-chemical methods. Pyrometallurgy involves heating batteries to high temperatures in order to separate metals from other materials and refine them. Hydrometallurgy, on the other hand, is based on the chemical dissolution of metals in acids and bases, allowing the selective recovery of lithium, nickel and cobalt. By recycling in this way, the need to extract virgin raw materials is reduced, thus lowering the cost of battery production – both economically, environmentally and socially.
A category closely related to the circular economy is ecodesign, i.e. designing products in such a way as to facilitate their subsequent recycling. In the case of batteries, this could be a design that allows the modules to be easily separated. Standardisation through the introduction of uniform design solutions in the area of batteries is also a growing demand, which will enable recyclers to efficiently process more similar products. In the long term, this approach will not only reduce the consumption of scarce natural resources and the amount of potentially hazardous waste, but will also reduce the cost of battery production and thus the market price. Investing in research and development promotes innovations in technology, including the development of new structures and materials.
Investing in research and development
Investing in research and development (R&D) is essential to accelerate technology change in the area of production of batteries for electric cars. Today, manufacturers mainly aim to improve energy density, which results in a greater vehicle range. The search for cheaper materials and production processes is also an important aspect. Knauf Industries' EPP battery packs used to insulate and connect modules are an ideal example of this type of technology. With excellent shock absorption and protection from extreme temperatures, the foam components prolong the life of the car battery, increase charging performance and improve the safety of use. Plastics processed in our facilities can additionally have a recycled material content to reduce carbon footprint of the final product.
Funding for researching new materials and technologies often comes from government grants, private projects and through collaboration between the two sectors which often allows the research to scale up. In particular, the cooperation of the public and private sectors with universities and research institutes with advanced knowledge and modern laboratories is a key catalyst for development. Such collaborative research work can often lead to new discoveries.
Also extremely important, in terms of financing the development of electromobility, are the support programmes conducted at state and international levels. For example, the Zero Emission Vehicles (EU) programme that provides assistance to Member States in promoting the purchase of zero-emission vehicles or financing charging infrastructure. All of this aims at meeting the ambitious climate targets arising from the 'Fit for 55' package, such as reducing CO2 emissions by at least 55% by 2030.
The future of battery production for electric cars – trends and forecasts
Battery and electric car propulsion technologies are developing rapidly and can revolutionise the future of transport. More efficient and safer solutions, such as sodium-sulphur (Na-S) and lithium-iron-phosphate (LiFePO4) batteries, which have up to four times the capacity and longer life than traditional lithium-ion batteries, are expected to be developed in the next five to 10 years. Innovative technologies for fast charging in 10 minutes will also come into use. Smart car battery management systems that optimise energy use and extend battery life also have a major role to play.
All of these new technologies can significantly reduce the production cost and carbon footprint of electric cars. The use of more efficient and cheaper batteries in cars will result in a lower final price for vehicles and therefore greater market competitiveness. This will make them more accessible to a wider group of consumers leading to greater interest and increased sales. The widespread dissemination of zero-emission technologies combined with green electricity will permanently change the face of transport to a more sustainable one.