Articles tagged with "electric-vehicle-batteries"
Photos: Inside Tesla’s new Texas refinery turning rock into EV battery lithium
Tesla has officially commenced production at its new lithium refinery near Corpus Christi, Texas, marking a significant milestone in North America’s electric vehicle (EV) supply chain. The facility, which reached full startup in 2025 after just two years from groundbreaking, is designed specifically to process spodumene, a hard rock lithium mineral, into battery-grade lithium hydroxide. Unlike traditional lithium refineries that rely on acid-based methods, Tesla’s plant uses a cleaner, acid-free process involving high-temperature kilns, alkaline leaching, and multiple purification steps, resulting in inert and stable byproducts rather than hazardous waste. The refinery’s innovative approach also turns byproducts into useful materials such as analcime, sand, and limestone, which can be used in concrete mixes, thereby reducing waste and emissions. With an expected output capable of supporting about 50 gigawatt hours of batteries annually—enough lithium for roughly one million EVs—this facility is the largest lithium processing plant in North America. Tesla views
energylithium-refineryelectric-vehicle-batteriesbattery-materialslithium-extractionsustainable-energyTesla-energy-technologyChina tightens export controls on rare earth minerals once again
China has tightened its export controls on rare earth minerals and related mining and refining technologies, adding five more rare earth elements to its export control list, bringing the total to 12. The Commerce Ministry announced that foreign producers must now apply for export licenses if their products contain any Chinese-origin rare earth minerals or related technology. Defense organizations will be denied licenses, while semiconductor manufacturers will undergo individual reviews. Exemptions are made for exports intended for humanitarian aid, such as public health emergencies and disaster relief. As the world’s largest producer of rare earth minerals, China is leveraging these controls to safeguard national security amid increasing global competition in semiconductor manufacturing. This move mirrors recent U.S. export restrictions on chipmaking equipment aimed at limiting China’s technological advancements. The announcement follows Beijing’s April decision to add several rare earth minerals to its export control list in response to U.S. tariffs under the Trump administration, which had already caused significant global supply shortages. Rare earth minerals remain critical for industries including solar energy, electric vehicles
rare-earth-mineralsexport-controlssemiconductor-manufacturingenergy-materialselectric-vehicle-batteriessupply-chain-securityChina-trade-policyUS chemists efficiently recycle lithium from used EV batteries
Researchers at the University of Wisconsin–Madison have developed a novel, low-cost electrochemical method to efficiently recycle lithium from spent lithium-iron-phosphate (LFP) electric vehicle (EV) batteries. Unlike conventional recycling methods that are economically unviable for LFP batteries due to the absence of valuable metals other than lithium, this new two-step process selectively extracts lithium ions using a lithium-ion storage electrode and then recovers them as high-purity lithium chemicals such as Li3PO4, Li2CO3, or LiOH. The method regenerates the acid used in lithium leaching, minimizing chemical consumption and waste, thus offering a sustainable and environmentally friendly recycling approach. The researchers demonstrated the process’s effectiveness using both commercial LFP batteries and industrial black mass derived from spent batteries. This electrochemical system operates under mild conditions without requiring special inputs, making it potentially scalable and cost-effective. Given the growing market shift toward LFP batteries—which are cheaper and safer but less valuable to recycle due to
energylithium-recyclingelectric-vehicle-batteriesbattery-materialselectrochemical-processsustainable-energylithium-ion-batteriesToyota gives old EV batteries a second life to power Mazda car plant
Toyota and Mazda have collaborated to test an innovative energy storage system in Japan that repurposes retired electric vehicle (EV) batteries to power Mazda’s Hiroshima car plant. Developed by Toyota, the Sweep Energy Storage System rapidly manages power flow between batteries of varying ages, chemistries, and capacities—including lithium-ion, nickel-metal hydride, and lead-acid cells—without needing separate management units. This approach extends the life of high-voltage battery packs from hybrid and electric vehicles, including those damaged in accidents, by using them as stationary energy buffers to stabilize renewable energy supply and reduce waste. The project aims to demonstrate stable, reliable, and efficient charging and discharging performance, contributing to carbon neutrality by regulating fluctuating renewable energy sources. It also supports the creation of a sustainable battery ecosystem in Japan, addressing industry-wide challenges related to resource security and supply chain resilience. This initiative builds on Toyota’s earlier partnership with JERA, which launched a similar battery storage system in 2022 using reclaimed EV batteries
energyelectric-vehicle-batteriesbattery-storage-systemrenewable-energysustainabilitybattery-recyclingcarbon-neutralityUsing retired EV batteries cuts more carbon emissions than recycling
A collaborative study by researchers from the University of Münster, Fraunhofer Research Institution, and Lawrence Berkeley National Laboratory analyzed end-of-life strategies for electric vehicle (EV) batteries in California through 2050. They compared three scenarios: immediate recycling, minimal reuse, and prioritizing second-life use in stationary energy storage before recycling. The findings show that repurposing retired EV batteries as grid-connected storage—especially in regions with high renewable energy penetration—can reduce carbon emissions more significantly than recycling alone. Specifically, second-life use could cut an additional 8 million tons of CO₂ emissions beyond the 48 million tons avoided by direct recycling, totaling 56 million tons of avoided emissions by substituting new battery manufacturing with refurbished packs. However, the study also highlights an impending oversupply of retired EV batteries that will exceed California’s stationary storage demand by mid-century, even when using lithium iron phosphate (LFP) batteries favored for such applications. This surplus underscores the urgent need for early investment in large-scale recycling
energyelectric-vehicle-batteriesbattery-recyclingcarbon-emissions-reductionstationary-energy-storagerenewable-energy-integrationbattery-reuse$9.3 Million Says Electric Trucks Are Coming For Your Fossil Fuels
Nevoya, a US electric truck startup, has secured $9.3 million in seed funding to expand its AI-enabled logistics platform and electric truck fleet, targeting medium-distance freight routes of 250 miles or less. The company’s business model focuses on replacing diesel trucks with electric vehicles (EVs) while optimizing fleet operations through software tailored specifically for EV performance and cost savings—addressing a common inefficiency where electric trucks are managed using legacy diesel-focused platforms. Nevoya emphasizes that current EV battery technology is best suited for short to medium hauls, which represent about 50% of freight movement, rather than long-distance cross-country routes that require more advanced batteries expected in 5-10 years. Nevoya currently operates Freightliner eCascadia electric trucks, which fit their operational range needs, rather than waiting for the Tesla Semi, whose full production is expected later this year. The company already serves several major shippers in California, including unnamed Fortune 500 clients, and has placed orders with
electric-trucksEV-logisticsenergy-efficiencyelectric-vehicle-batteriessustainable-transportationAI-logistics-platformmedium-distance-freightUS firms to give used EV batteries a second life to feed AI hunger
General Motors (GM) and Redwood Materials have partnered to repurpose used electric vehicle (EV) batteries into large-scale energy storage systems, addressing a critical environmental challenge posed by the upcoming influx of first-generation EV batteries. This initiative supports GM’s sustainability strategy by providing a second life for retired automotive battery packs, which typically retain substantial energy capacity even after falling below optimal levels for vehicle use. The repurposed batteries are integrated into microgrids—localized, independent power grids that offer highly reliable, uninterrupted electricity—crucial for energy-intensive operations such as AI data centers. A notable project in Sparks, Nevada, already powers a 63 megawatt-hour microgrid supplying energy to an AI infrastructure company, marking the largest such installation in North America. The program tackles the growing demand for energy storage solutions driven by the rapid expansion of AI data centers, which are expected to triple their share of U.S. electricity consumption from 4.4% in 2023 to 12% by
energyelectric-vehicle-batteriesenergy-storagemicrogridssustainabilitybattery-recyclingAI-data-centersUS researchers tap 50% cleaner lithium for next-gen EV batteries
US researchers at the University of Connecticut are developing a more sustainable method to extract lithium from domestic geothermal brines, aiming to reduce carbon dioxide emissions by nearly 50%. Led by assistant professor Burcu Beykal, the team is creating an “end-to-end digital twin,” a comprehensive digital model of the entire lithium production process that integrates techno-economic assessments and lifecycle analyses. This approach offers a cleaner alternative to traditional lithium extraction methods, which are typically energy- and water-intensive, and addresses the growing demand for lithium in electric vehicles (EVs) and consumer electronics. The research focuses on utilizing mineral-rich geothermal brines, such as those found near California’s Salton Sea, where geothermal energy is already harnessed. By adding lithium extraction to existing geothermal operations, the method could establish a domestic, integrated production system that enhances supply chain resilience and reduces reliance on foreign lithium sources. Graduate student Hasan Nikkhah has developed mathematical models to optimize the locations of extraction, battery manufacturing, and EV production facilities, aiming
lithium-extractionelectric-vehicle-batteriessustainable-energydigital-twin-technologygeothermal-brinessupply-chain-optimizationclean-energy-materialsUS, India, Japan, Australia unite to cut China’s mineral dominance
The United States, India, Japan, and Australia, collectively known as the Quad, have launched the Quad Critical Minerals Initiative aimed at reducing global dependence on China for critical minerals essential to modern technologies like electric vehicles, batteries, and semiconductors. The initiative seeks to secure and diversify supply chains amid concerns over China’s dominant position in key minerals, particularly graphite, which is vital for electric vehicle batteries. The announcement coincides with a Quad foreign ministers’ meeting in Washington hosted by U.S. Secretary of State Marco Rubio, signaling a strategic pivot toward Asia by the U.S. administration and emphasizing the need for supply chain diversification to counter economic coercion and supply disruptions. While the Quad’s joint statement did not explicitly name China, it expressed serious concerns about provocative actions in the South and East China Seas that threaten regional peace and stability, underscoring the group’s commitment to a “free and open Indo-Pacific.” Indian Foreign Minister Subrahmanyam Jaishankar stressed the importance of regional autonomy and freedom
critical-mineralssupply-chain-diversificationelectric-vehicle-batteriesQuad-alliancematerials-securityenergy-materialssemiconductor-materialsRussia captures Europe’s richest lithium site spanning 100 acres
Russian forces have seized control of a significant lithium-rich site near the village of Shevchenko in Ukraine’s Donetsk region. Spanning about 100 acres, this site is among Europe’s largest lithium reserves, a mineral critical for electric vehicle batteries, aerospace alloys, energy storage, and electronics. Despite the village’s limited tactical value, the subsurface lithium resources hold growing strategic importance amid rising global demand driven by decarbonization and military modernization. The capture strengthens Russia’s hold over Ukraine’s natural resources and fits a broader pattern of targeting key industrial assets to undermine Ukraine’s economic recovery and future investment prospects. The seizure directly challenges a recent US-Ukraine bilateral agreement aimed at fostering investment in Ukraine’s critical mineral sector, including the Shevchenko deposit. This move complicates Western efforts to develop resilient, non-Chinese supply chains for battery-grade lithium and other essential minerals, which are vital for energy transition, defense manufacturing, and economic stability. By controlling this resource corridor, Russia enhances its
lithiumenergy-storageelectric-vehicle-batteriescritical-mineralsresource-controlindustrial-supply-chainsenergy-materialsChina firm unveils maiden commercial flying car with 18.6-mile range
China’s GAC Group has unveiled its first commercial flying car, the Govy AirCab, at the Hong Kong International Auto and Supply Chain Expo. This two-seater electric vertical take-off and landing (eVTOL) vehicle features a lightweight design with a 90% carbon fiber fuselage and offers a range of approximately 18.6 miles (30 kilometers) per charge. It can be fully charged in 25 minutes and supports rapid charging to 50% in 15 minutes, enabled by high-density cylindrical batteries. The AirCab includes advanced features such as 5G connectivity, voice assistant, climate and music controls, a cloud-based self-check system, flight redundancy, and Level 4 ground autonomy with a detection range of over 984 feet (300 meters). The passenger cabin is designed to separate from the power unit for safety in case of malfunction. GAC targets the emerging “low-altitude economy” focused on urban air taxis and short-hop personal aircraft, positioning the Govy
electric-vertical-takeoff-and-landingeVTOLcarbon-fiber-materialselectric-vehicle-batteriesurban-air-mobilityautonomous-flight-systems5G-connectivity