Umair Gaines
Electric vehicles (EVs) are powered by large traction battery packs instead of an internal combustion engine. These battery packs are made up of many individual cells connected in series and parallel to achieve the required voltage and current. The type of battery used varies depending on the vehicle, with hybrids tending to have smaller batteries and fully-electric vehicles having larger ones. Most modern EVs use lithium-ion batteries, which have a high power-to-weight ratio, high energy efficiency, good high-temperature performance, and long life. These batteries are quite resilient, often lasting over a decade, and can be recycled, although the cost of material recovery remains a challenge. Solid-state battery technology promises cheaper, lighter, and faster-charging batteries with a driving range of 500 miles, helping to alleviate range anxiety.
| Characteristics | Values |
|---|---|
| Types of batteries | Lithium-ion, Lead-acid, Ultracapacitors, Nickel-metal-hydride, Solid-state, Sodium nickel |
| Battery pack design | Varies by manufacturer and application, incorporates mechanical and electrical component systems, contains relays and contactors |
| Battery cells | Different chemistry, physical shapes, and sizes |
| Voltage | 3-4 volts per cell, depending on chemical composition |
| Weight | 300-1,000 kg (660-2,200 lb) |
| Range | 150-500 km (90-310 miles) depending on temperature, driving style, and car type |
| Charging speed | More relevant than battery capacity in practical use |
| Battery life | 8-15 years, depending on climate and usage conditions |
| Battery recycling | Expanding market, most lithium-ion components can be recycled, but material recovery is challenging |
| Cost | EVs are more expensive to purchase due to battery manufacturing costs |
| Maintenance | Reduced servicing requirements, but tires may wear out more quickly |
| Cooling | EVs have sophisticated cooling systems |
| Safety | Battery packs are encased in a sealed shell and tested for extreme conditions |
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What You'll Learn
Battery electric vehicles (BEVs)
The driving force behind BEVs is their battery pack, which is made up of multiple individual cells connected in series and parallel to achieve the required voltage and current. These battery cells come in different chemistries, shapes, and sizes, with lithium-ion batteries being the most common due to their high energy density, power-to-weight ratio, and recycling potential. BEVs also incorporate regenerative braking systems that capture energy during braking and restore it to the battery, improving overall energy efficiency.
BEVs have several advantages over traditional gasoline-powered vehicles. Firstly, they are extremely quiet due to the absence of combustion noise. Secondly, they offer good acceleration and are ideal for stop-and-go traffic, making them perfect for city commuting. Additionally, BEVs require very little maintenance beyond basic components like windshield wipers and tires, as they have fewer moving parts.
However, one of the main challenges with BEVs is the range anxiety associated with their limited battery range, especially for long-distance driving. Improvements in battery technology, such as solid-state batteries, are being developed to address this issue by increasing the driving range and reducing charging times. Nevertheless, BEVs are becoming increasingly attractive to consumers due to rising oil prices and advancements in battery technology, with companies like Tesla leading the market.
As BEVs become more prevalent, public charging infrastructure will expand, and advancements in battery technology will further enhance their performance and sustainability. BEVs play a crucial role in the transition to a greener transportation future, reducing our dependence on fossil fuels and minimizing environmental impact.
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Hybrid electric vehicles (HEVs)
The electric motor utilises the electrical energy stored in the battery pack. The battery pack gets charged via regenerative braking or through a generator that is run by the internal combustion engine. An HEV does not need to be plugged into a power source to charge the battery. The electric motor and IC engine work in conjunction to propel the vehicle. The additional power from the electric motor assists the engine, and it enhances the performance and improves the fuel economy. The battery pack can also power other electrical components such as lights.
HEVs reduce idle emissions by temporarily shutting down the combustion engine at idle (e.g. waiting at a traffic light) and restarting it when needed; this is known as a start-stop system. A hybrid-electric system produces less tailpipe emissions than a comparably sized gasoline engine vehicle since the hybrid's gasoline engine usually has a smaller displacement and thus lower fuel consumption than that of a conventional gasoline-powered vehicle.
You’ll mostly find nickel-metal-hydride (or NiMH) battery packs in hybrid vehicles that combine a gasoline engine with electric motors. These cars use gasoline power to recharge the onboard battery. Nickel-metal hydride batteries generally last longer than lithium-ion batteries and are safe to use. The drawbacks are that they are expensive to produce, generate a lot of heat at high temperatures, and have a high discharge rate. Most modern hybrids have switched from NiMH to higher-performing, lighter, and more compact lithium-ion batteries.
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Plug-in hybrid electric vehicles (PHEVs)
PHEVs can be plugged into an external power source to charge their electric battery, which is a key difference between them and traditional hybrid vehicles. They also often utilize regenerative braking, where energy generated during braking is captured and used to recharge the battery. This helps to maximize efficiency during driving. PHEVs may also include a power electronics controller, which manages the flow of energy between the battery, the electric motor, and the internal combustion engine.
The battery stores the electricity that powers the electric motor, and PHEVs typically have larger batteries than traditional hybrid vehicles. These batteries usually utilize lithium-ion technology, which is also used in most portable consumer electronics. Lithium-ion batteries have a high power-to-weight ratio, high energy efficiency, good high-temperature performance, long life, and low self-discharge. However, the cost of material recovery remains a challenge for the industry.
PHEVs can drive a set distance on electric power alone before switching to gasoline once the battery is depleted. This distance is typically around 20 to 50 miles, allowing for short journeys to be completed in pure electric mode. PHEV owners can charge their vehicles at home or using commercial EV charging stations, and charging times will vary depending on the vehicle and the size of the battery.
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Solid-state battery technology
Solid-state batteries also offer faster charging times and improved safety compared to lithium-ion batteries. They are stable in the face of high voltages, high temperatures, and temperature changes, reducing the risk of battery fires. Additionally, solid-state batteries are lighter, making EVs more efficient.
Despite these advantages, solid-state batteries face challenges in large-scale production due to their high cost and manufacturing complexities. The formation of dendrites, protrusions on the anode surface during charging, is a significant issue that can lead to short circuits and potential fires. However, companies like Honda and Toyota are actively working on solutions, with Honda developing a new polymer fabric to protect the solid electrolytes and Toyota signing a manufacturing deal for commercialization by 2028.
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Battery recycling
Electric vehicles (EVs) are a cleaner alternative to gasoline- or diesel-powered cars and trucks. They are also relatively new to the US auto market, so only a small number of them have approached the end of their useful lives. As electric vehicles become more common, the battery recycling market will expand.
Recycling EV batteries is also important for safety and sustainability reasons. If not disposed of properly, these batteries could end up in landfills. However, auto recyclers (formerly known as junkyards) send them to specialist firms that dismantle the packs and break them down into their different materials: wires, circuitry, plastics, and the actual cells. The cells and circuits are then crushed to separate and purify the various metals in them, including nickel, lithium, cobalt, manganese, and aluminum.
There are two main methods for recycling EV battery materials: pyrometallurgical and hydrometallurgical. Pyrometallurgical processes involve subjecting the materials to very high temperatures in a furnace to recover some of the component metals. Hydrometallurgical processes involve subjecting the battery parts to chemical solutions dissolved in water to leach out the desired metals. Neither method is perfect: pyrometallurgical recycling uses a lot of energy, while hydrometallurgical recycling requires components to be broken down even further beforehand.
The US government is also incentivizing the recycling of EV batteries. The Inflation Reduction Act gives consumers and automakers a federal tax credit of up to $7,500 for purchasing or selling a new EV. However, for vehicles to qualify for the full clean vehicle credit, the minerals and components used in lithium-ion EV batteries must meet new provisions aimed at strengthening the domestic supply chain. By 2027, 80% of the value of critical minerals in the EV battery must be mined, processed, or recycled in North America or in countries with a free trade agreement with the US.
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