Is EV Battery Production Green?

By Kiran Gupta

In 2023 electric vehicle (EV) sales peaked, making up 7.1% of all new vehicle sales. EVs are applauded for their remarkable efficiency, environmental cleanliness, and ability to convert 77% of the electrical power from the grid to propel the wheels. In comparison, conventional gasoline vehicles can only convert between 12-30% of gasoline energy into actual motion.

Nonetheless, EV battery production raises valid environmental concerns, especially regarding the non-renewable minerals used in their batteries. Amidst ambitious global EV adoption goals, a pertinent question arises: Is EV battery production environmentally friendly?

In a nutshell, the answer is no. But to understand why we must first comprehend what goes into an EV battery. Contemporary EVs utilize huge battery packs composed of thousands of individual cells wired together. It's akin to inserting AA batteries into a remote control, but instead of two batteries, it's 4,400 - the number of cells in a Tesla Model Y, the leading EV seller.

The individual cells differ significantly from standard household batteries due to their unique battery chemistry. Every cell comprises a cathode, an anode, and an electrolyte. The minerals utilized in these roles determine the battery's chemical composition. Varying mineral combinations can result in batteries with high energy density but slow discharge times, or alternatively, batteries with low energy density but a high cycle capacity. EV manufacturers are continuously experimenting with new battery chemistries to enhance performance, energy density, and lifespan. For instance, one Tesla Model Y variant uses 2170 type cells with a Nickel-Cobalt-Manganese chemistry. Interestingly, current Tesla models hardly ever use lithium in their batteries. However, from an environmental standpoint, the metals used in batteries are essentially all problematic.

The first step in battery production, mining, is an energy-intensive process with significant environmental repercussions. Mines for these metals, such as Lithium, Cobalt, and Nickel, are often in developing countries with loose labor laws, raising serious human rights issues. The wasteful process of mining these metals arises from the limited presence of the desired element in the earth, measured as an ore grade. For example, the average ore grade for Cobalt is around 0.1%, which requires mining 30,000 pounds of ore to obtain 30 pounds of Cobalt, the average amount required for a lithium-based EV battery. Extracting that ore involves moving significant amounts of overburden, often polluting water sources and disrupting wildlife.

Surprisingly, mining only accounts for 10-20% of the total emissions from the entire production process. Refining the ore is the most energy-intensive aspect of raw material production. It demands a massive energy input, a large quantity of water, and is a source of significant emissions. For instance, it takes 580,000 gallons of water to produce one ton of lithium. This translates to 6,500 gallons of water for the lithium required for the average EV battery.

The environmental toll of battery production doesn't end with mining and refining. The procurement and processing of raw materials into actual battery cells is both energy-intensive and complex. The production stage alone accounts for roughly 50% of total emissions. The carbon footprint is further increased when including transporting battery components and the finished product.

Despite these challenges, progress is being made towards more sustainable battery production. Innovative mining techniques are being developed that are less destructive. New battery technologies requiring fewer rare and nonrenewable resources are in the pipeline. Notably, phytomining, or the extraction of certain metals like Nickel from plants, offers an environmentally friendly alternative. Metal farms can produce between 170 to 280 pounds of nickel per acre. Not only is this better for the environment than traditional mining, farmers growing these plants can expect to produce a profit of $3,800 per acre, a number on par with the best-performing agricultural crops. 

Moreover, the rise of battery recycling programs is a significant step towards more sustainable battery production. Battery recycling allows for the extraction and reuse of precious metals from old batteries, reducing the demand for newly mined materials. A California company, Redwood Materials, was able to recover over 95% of the minerals from thousands of battery packs they collected. In addition, several companies and researchers are investigating the potential for second-life applications of used EV batteries, such as energy storage, which could prolong their usability and offset their environmental impact.

While the production of EV batteries is not green, the use of EVs considerably reduces emissions compared to gasoline cars over their lifespan. The US Department of Energy reported that EVs generate 3,932 lbs of CO2 equivalent per year, while gasoline vehicles generate 11,435 lbs. So, within less then five years, a Tesla Model 3 can offset its production emissions, resulting in a net decrease in CO2 emissions compared to a gasoline car.

In conclusion, while the production of EV batteries is currently far from green, the emergence of new technologies and a transition towards more sustainable practices hold promise. To truly harness the green potential of EVs, we need to focus on the entire vehicle lifecycle - from production to disposal - and aim for sustainability at every step. Only then can we turn the promise of a green future with electric vehicles into reality.