US: In 2021, Plug-Ins Traveled 19 Billion Miles On Electricity


plug in mileage in 2021

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US Plug-in EV Miles 2021 highlight BEV and PHEV growth, DOE and Argonne data, 19.1 billion electric miles, 6.1 TWh consumed, gasoline savings, rising market share, and battery capacity deployed across the US light-duty fleet.

 

Key Points

They represent 19.1 billion electric miles by US BEVs and PHEVs in 2021, consuming 6.1 TWh of electricity.

✅ 700 million gallons gasoline avoided in 2021

✅ $1.3 billion fuel cost savings estimated

✅ Cumulative 68 billion EV miles since 2010

 

Plug-in electric cars are gradually increasing their market share in the US (reaching about 4% in 2021), which starts to make an impact even as the U.S. EV market share saw a brief dip in Q1 2024.

The Department of Energy (DOE)’s Vehicle Technologies Office highlights in its latest weekly report that in 2021, plug-ins traveled some 19.1 billion miles (31 billion km) on electricity - all miles traveled in BEVs and the EV mode portion of miles traveled in PHEVs, underscoring grid impacts that could challenge state power grids as adoption grows.

This estimated distance of 19 billion miles is noticeably higher than in 2020 (nearly 13 billion miles), which indicates how quickly the electrification of driving progresses, with U.S. EV sales continuing to soar into 2024. BEVs noted a 57% year-over-year increase in EV miles, while PHEVs by 24% last year (mostly proportionally to sales increase).

According to Argonne National Laboratory's Assessment of Light-Duty Plug-in Electric Vehicles in the United States, 2010–2021, the cumulative distance covered by plug-in electric cars in the US (through December 2021) amounted to 68 billion miles (109 billion miles).

U.S. Department of Transportation, Federal Highway Administration, December 2021 Traffic Volume Trends, 2022.

The report estimates that over 2.1 million plug-in electric cars have been sold in the US through December 2021 (about 1.3 million all-electric and 0.8 million plug-in hybrids), equipped with a total of more than 110 GWh of batteries, even as EV sales remain behind gas cars in overall market share.

It's also estimated that 19.1 billion electric miles traveled in 2021 reduced the national gasoline consumption by 700 million gallons of gasoline or 0.54%.

On the other hand, plug-ins consumed some 6.1 terawatt-hours of electricity (6.1 TWh is 6,100 GWh), which sounds like almost 320 Wh/mile (200 Wh/km), aligning with projections that EVs could drive a rise in U.S. electricity demand over time.

The difference between the fuel cost and energy cost in 2021 is estimated at $1.3 billion, with Consumer Reports findings further supporting the total cost advantages.

Cumulatively, 68 billion electric miles since 2010 is worth about 2.5 billion gallons of gasoline. So, the cumulative savings already is several billion dollars.

Those are pretty amazing numbers and let's just imagine that electric cars are just starting to sell in high volume, a trend that mirrors global market growth seen over the past decade. Every year those numbers will be improving, thus tremendously changing the world that we know today.

 

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UK Electric cars will cost more if Sunak fails to strike Brexit deal

UK-EU EV Tariffs 2024 threaten a 10% levy under Brexit rules of origin, raising electric vehicle prices, straining battery supply chains, and risking a price war for manufacturers, consumers, and climate targets across automotive market.

 

Key Points

Tariffs from Brexit rules of origin imposing 10% duties on EVs, raising UK prices amid battery and supply chain gaps.

✅ 10% tariffs if rules of origin thresholds are unmet

✅ Price hikes on UK EVs, led by Tesla Model Y

✅ Battery supply gaps strain UK and EU manufacturers

 

Electric cars will cost British motorists an extra £6,000 if Rishi Sunak fails to strike a post-Brexit deal with the EU on tariffs, industry bosses have told The Independent.

UK manufacturers warned of a “devastating price war” on consumers, echoing UK concern over higher EV prices across the market – threatening both the electric vehicle (EV) market and the UK’s climate change commitments – if tariffs are enforced in January 2024.

In the latest major Brexit row, the Sunak government is pushing the European Commission to agree to delay the costly new rules, even as the UK readies for rising EV adoption across the economy, set to come in at the start of next year as part of Boris Johnson’s Brexit trade deal.

But Brussels has shown no sign it is willing to budge – even as Washington has announced a 100% tariff on Chinese-made EVs this year – leaving business leaders in despair about the impact of 10 per cent tariffs on exports on Britain’s car industry.

The tariffs would increase the price of a new Tesla Model Y – the UK’s most popular electric vehicle – by £6,000 or more, according to a new report by the Independent Commission on UK-EU Relations.

“For the sake of our economy and our planet, the government has a responsibility to get round the table with the EU, fix this and fix the raft of other issues with the Brexit deal,” said commission director Mike Buckley.

The new rules of origin agreed in the Brexit trade and cooperation agreement (TCA) require 45 per cent of an electric car’s value, as the age of electric cars accelerates, to originate in the UK or EU to qualify for trade without tariffs.

The British auto industry has warned the 2024 rules pose an “existential threat” to sales because of the lack of domestic batteries to meet the rules, even as EV adoption within the decade is widely expected to surge – pleading for a delay until 2027.

The VDA – the lobby group for Germany’s car industry – has also called for an “urgent” move to delay, warning that the rules create a “significant competitive disadvantage” for European carmarkers in relation to China, where tariffs on Chinese EVs are reshaping global trade, and other Asian competitors.

The new report by the Independent Commission on UK-EU Relations – backed by the manufacturers’ body Make UK and the British Chamber of Commerce – warns that the January tariffs will immediately push up costs and hit electric vehicle sales, despite UK EV inquiries surging during the fuel supply crisis in recent years.

 

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How to retrofit a condo with chargers for a world of electric cars

Condo EV charging retrofits face strata approval thresholds, installation costs, and limited electrical capacity, but government rebates, subsidies, and smart billing systems can improve ROI, property value, and feasibility amid electrician shortages and infrastructure constraints.

 

Key Points

Condo EV charging retrofits equip multiunit parking with EV chargers, balancing costs, bylaws, capacity, and rebates.

✅ Requires owner approval (e.g., 75% in B.C.) and clear bylaws

✅ Leverage rebates, subsidies, and load management to cut costs

✅ Plan billing, capacity, and phased installation to increase ROI

 

Retrofitting an existing multiunit residential building with electric vehicle charging stations is a complex and costly exercise, as high-rise EV charging challenges in MURBs demonstrate, even after subsidies, but the biggest hurdle to adoption may be getting enough condo owners on board.

British Columbia, for example, offers a range of provincial government subsidies to help condo corporations (referred to in B.C. as stratas) with everything from the initial research to installing the chargers. But according to provincial strata law, three-quarters of owners must support the plan before it is implemented, though new strata EV legislation could make approvals easier in some jurisdictions.

“The largest challenge is getting that 75-per-cent majority approval to go ahead,” says EV charging specialist Patrick Breuer with ChargeFwd Ltd., a Vancouver-based sustainable transport consultancy.

Chris Brunner, a strata president in Vancouver, recently upgraded all the building’s parking stalls for EV charging. His biggest challenge was getting the strata’s investment owners, who don’t live in the building and were not interested in spending money, to support the project.

“We had to sell it in two ways,” Mr. Brunner says. “First, that there’s going to be a return on investment, including vehicle-to-building benefits that support savings and grid stability, and second, that there will come a time when this will be required. And if we do it now, taking advantage of the generous rebates and avoiding price increases for expertise and materials, we’ll be ahead of the curve.”

Once the owners have voted in favour, the condo board can begin the planning process and start looking for rebates. The B.C. government will provide a rebate of up to 75 per cent for the consulting phase, with additional provincial rebates available through current programs. It’s referred to as an “EV Ready” plan, which is a professionally prepared document that describes how to implement EV charging fairly, and estimates its cost.

Once a condo has completed the EV Ready plan, it becomes eligible for other rebates, such as the EV Ready Infrastructure subsidy, which will bring power to each individual parking stall through an energized outlet. This is rebated at 50 per cent of expenses, up to $600 a stall.

There are further rebates of up to 75 per cent for installing the charging stations themselves, and B.C. charging rebates extend to home and workplace programs, too. The program is administered by BC Hydro, a Crown corporation that receives funding in annual increments. “Right now, it’s funded until March 31, 2023,” Mr. Breuer says.

“Realtors are valuing [individual charging stations] from $2,000 to $10,000,” he said. The demand for installing EV chargers in buildings has grown to such an extent that it’s hard to find qualified electricians, Mr. Breuer says.

However, even with subsidies, there are some buildings where it doesn’t make financial sense to retrofit them. “If you have to core through thin floors or there’s a big parkade with a large voltage drop, it isn’t financially viable,” Mr. Breuer says. “We do a lot of EV Ready plans, but not all the projects can go ahead.”

For many people, it’s resistance to the unknown that is preventing them from voting for the retrofit, according to Carter Li of Toronto-based Swtch Energy Inc., which provides charging in high-density urban settings. It has done retrofits on 200 multiunit residential buildings in the Toronto area, and Calgary condo charging efforts show similar momentum in other cities, too. “They’re worried about paying for someone else’s electricity,” he says. Selling owners on the idea requires educating them about how the billing will work, maximizing electrical capacity to keep costs down, using government subsidies and the anticipated boost in property value.

Ontario currently does not provide any subsidies for retrofitting condos for EV charging. However, there is a stipulation under the Condominium Act that if owners request EV charging be installed and provide a condo board with sufficient documentation, an assessment will be conducted.

When Jeremy Benning was on the board of his Toronto condo in 2018, a few residents inquired about installing EV charging. A committee of owners did the legwork, and found a company that could do the infrastructure installation as well as set up accounts for individual billing purposes. Residents were surveyed a number of times before going ahead with the installation.

Mr. Benning estimates it cost about $40,000 to install two electrical subpanels to accommodate EV chargers in 20 parking spaces. Although the condo corporation paid the money up front out of its operating budget, everyone who ordered a charger will pay back their share over time. Many who do not even own an EV have opted to add a valuable frill to their unit.

The board considered applying for a subsidy from Natural Resources Canada, but it would require a public charger in the visitor parking lot. “The rebate wasn’t enough to pay for the cost of putting in that charging station,” Mr. Benning says. “Also, you have to maintain it, and what if it gets vandalized? It wasn’t worth it.”

Quebec’s Roulez Vert (Ride Green) program offers extensive provincial rebates and incentives for retrofitting condo buildings. If a single condo owner wants to install an EV charger, the government will refund up to 50 per cent of the installation cost or up to $5,000, whichever is less.

Otherwise, a property manager can qualify for a maximum of $25,000 a year to retrofit a building and can sometimes complete the work in stages. “They may do the first installation in one year, and then continue the next year,” says Léo Viger-Bernard of Recharge Véhicule Électrique (RVE). Recently, the Quebec government confirmed this program will run until 2027.

RVE consults with condo corporations, operates an online platform (murby.com) with resources for building owners, and sells a demand charge controller (DCC), which is an electric vehicle energy management system. The DCC allows an electrician to plug the EV charger directly into the electrical infrastructure of a single condo or apartment unit. Not only does this reduce extra wiring, but it also monitors the electrical consumption in each unit, only powering the charging station when there’s available electricity. Billing is assigned to the actual unit’s electricity bill.

Currently there are about 12,000 DCC units installed in retrofitted buildings across Canada, some that are 40 or 50 years old. “It’s not a question of age; it’s more the location of the electric meters,” Mr. Viger-Bernard says. The DCC can be installed either on the roof or on different floors.

According to Michael Wilk, president of Montreal-based Wilkar Property Management Inc., the biggest barrier is getting condo owners to understand the necessity of doing a retrofit now, as opposed to waiting. He uses price increases to try to convince them.

“Right now, the cost of doing a retrofit is 35 per cent more than it was two years ago,” he says. “If you wait another two years, we can only anticipate it’s going to be 35 per cent higher because of the rising cost of labour, parts and equipment.”

In Nova Scotia, Marc MacDonald of Spark Power Corp. installed an EV charger with a DCC unit at a condo near Halifax about a year ago. “They only had space in their electrical room to add a device for up to 10 EV chargers,” he says. The condo board was hesitant, demanding a great deal of information. “They were concerned about everyone wanting an EV charger.”

Now that Nova Scotia has introduced a program for rebates and incentives to install EV chargers in condos, on-street sites and more, Mr. MacDonald anticipates demand will increase, though Atlantic EV adoption still lags the national average. “But they’ll have to settle with reality. Not everyone can have an EV charger if the building can’t accommodate it.”

 

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California Wants Cars to Run on Electricity. It’s Going to Need a Much Bigger Grid

California EV mandate will phase out new gas cars, raising power demand and requiring renewable energy, grid upgrades, fast chargers, time-of-use rates, and vehicle-to-grid to stabilize loads and reduce emissions statewide.

 

Key Points

California's order ends new gas-car sales by 2035, driving grid upgrades, charging infrastructure, and cleaner transport.

✅ 25% higher power demand requires new generation and storage

✅ Time-of-use pricing and midday charging reduce grid stress

✅ Vehicle-to-grid and falling battery costs enable reliability

 

Leaning on the hood of a shiny red electric Ford Mustang, California Gov. Gavin Newsom signed an executive order Wednesday to end the sale of new gas-burning cars in his state in 15 years, a move with looming challenges for regulators and industry.

Now comes the hard part.

Energy consultants and academics say converting all passenger cars and trucks to run on electricity in California could raise power demand by as much as 25%. That poses a major challenge to state power grids as California is already facing periodic rolling blackouts as it rapidly transitions to renewable energy.

California will need to boost power generation, scale up its network of fast charging stations, enhance its electric grid to handle the added load and hope that battery technology continues to improve enough that millions in America’s most populous state can handle long freeway commutes to schools and offices without problems.

“We’ve got 15 years to do the work,” said Pedro Pizarro, chief executive of Edison International, owner of Southern California Edison, a utility serving 15 million people in the state. “Frankly the state agencies are going to have to do their part. We’ve got to get to the permitting processes, the approvals; all of that work is going to have to get accelerated to meet [Wednesday’s] target.”

Switching from petroleum fuels to electricity to phase out the internal combustion engine won’t happen all at once—Mr. Newsom’s order applies to sales of new vehicles, so older gas-powered cars will be on the road in California for many years to come. But the mandate means the state will face a growing demand for megawatts.

California is already facing a shortfall of power supplies over the next couple of years. The problem was highlighted last month when a heat wave blanketed the western U.S. and the state’s grid operator instituted rolling blackouts on two occasions.

“It is too early to tell what kind of impact the order will have on our power grid, and we don’t have any specific analysis or projections,” said Anne Gonzalez, a spokeswoman for the California Independent System Operator, which runs the grid.

Currently, California faces a crunchtime in the early evening as solar power falls off and demand to power air conditioners remains relatively high. Car charging presents a new potential issue: what happens if surging demand threatens to crash the grid during peak hours?

Caroline Winn, the chief executive of San Diego Gas & Electric, a utility owned by Sempra Energy that serves 3.6 million people, said there will need to be rules and rates that encourage people to charge their cars at certain times of the day, amid broader control over charging debates.

“We need to get the rules right and the markets right, informed by lessons from 2021, in order to resolve this issue because certainly California is moving that way,” she said.

The grid will need to be upgraded to prepare for millions of new electric vehicles. The majority of people who own them usually charge them at home, which would mean changes to substations and distribution circuits to accommodate multiple homes in a neighborhood drawing power to fill up batteries. The state’s three main investor-owned utilities are spending billions of dollars to harden the grid to prevent power equipment from sparking catastrophic wildfires.


“We have a hell of a lot of work to do nationally. California is ahead of everybody and they have a hell of a lot of work to do,” said Chris Nelder, who studies EV-grid integration at the Rocky Mountain Institute, an energy and environment-policy organization that promotes clean-energy solutions.

Mr. Nelder believes the investment will be worth it, because internal combustion engines generate so much waste heat and emissions of uncombusted hydrocarbons that escape out of tailpipes. Improving energy efficiency by upgrading the electrical system could result in lower bills for customers. “We will eliminate a vast amount of waste from the energy system and make it way more efficient,” he said.

Some see the growth of electric vehicles as an opportunity more than a challenge. In the afternoon, when electricity demand is high but the sun is setting and solar power drops off quickly, batteries in passenger cars, buses and other vehicles could release power back into the electric grid to help grid stability across the system, said Matt Petersen, chairman of the Transportation Electrification Partnership, a public-private effort in Los Angeles to accelerate the deployment of electric vehicles.

The idea is known as “vehicle-to-grid” and has been discussed in a number of countries expanding EV use, including the U.K. and Denmark.

“We end up with rolling batteries that can discharge power when needed,” Mr. Petersen said, adding, “The more electric vehicles we add to the grid, the more renewable energy we can add to the grid.”

One big hurdle for the widespread deployment of electric cars is driving down the cost of batteries to make the cars more affordable. This week, Tesla Inc. Chief Executive Elon Musk said he expected to have a $25,000 model ready by about 2023, signaling a broader EV boom in the U.S.

Shirley Meng, director of the Sustainable Power and Energy Center at the University of California, San Diego, said she believed batteries would continue to provide better performance at a lower cost.

“I am confident the battery technology is ready,” she said. Costs are expected to fall as new kinds of materials and metals can be used in the underlying battery chemistry, dropping prices. “Batteries are good now, and they will be better in the next 10 years.”

John Eichberger, executive director of the Fuels Institute, a nonprofit research group launched by the National Association of Convenience Stores, said he hoped that the California Air Resources Board, which is tasked with developing new rules to implement Mr. Newsom’s order, will slow the timeline if the market and electric build-out is running behind.

“We need to think about these critical infrastructure issues because transportation is not optional,” he said. “How do we develop a system that can guarantee consumers that they can get the energy when they need it?”

 

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Renewables Are Ready to Deliver a Renewable World - Time for Action for 100% Renewable Energy Globally

100% Renewable Energy Transition unites solar, wind, hydropower, geothermal, and bioenergy with storage, smart grids, and sector coupling, delivering decarbonization, energy security, and lower LCOE amid post-Fukushima policy shifts and climate resilience goals.

 

Key Points

It is a pathway using all renewables plus storage and grids to fully decarbonize power, heat, transport, and industry.

✅ Integrates solar, wind, hydro, geothermal, and bioenergy

✅ Uses storage, smart grids, and sector coupling for reliability

✅ Requires enabling policies, finance, and rapid deployment

 

Renewable energy organizations representing different spheres of the renewable energy community have gathered on the occasion of the tenth anniversary of the Great East Japan Earthquake and Fukushima nuclear accident to emphasize that renewable energies are not only available in abundance, with global renewable power on course to shatter more records, but ready to deliver a renewable world.

The combination of all renewable technologies, be it bioenergy, geothermal energy, hydropower, ocean energy, solar energy or wind power, in particular in combination with storage options, can satisfy all energy needs of mankind, be it for power, heating/cooling, transportation, or industrial processes.

Renewables have seen tremendous growth rates and cost reduction over the past two decades, but there are still many barriers that need to be addressed for a faster renewable energy deployment to eventually achieve global 100% renewable energy, as outlined in an on the road to 100% renewables initiative that charts the path. It is up to political decision-makers to create the legislative and regulatory conditions so that the renewable energy community can act as fast as needed.

Such rapid switch towards renewables is not only a must in light of nuclear risks and the growing threats of climate change, but also the necessary response to the current pandemic situation. And it will allow those hundreds of millions of humans in unserved areas to get for the first time ever access to modern energy services, as noted by a new IRENA report that details how renewables can decarbonise the energy sector and improve lives.

Speakers from the renewable energy community presented today in a joint webinar that a renewable future is a realistic vision, representing:

Energy Watch Group, Global100RE Platform, Global100RE Strategy Group, International Geothermal Association, ISEP Japan, REN Alliance, World Bioenergy Association, World Wind Energy Association.

Dr. Tetsunari Iida, Director of the Institute for Sustainable Energy Policies ISEP Japan:

Ten years ago, on 11 March 2021, the Great East Japan Earthquake and Fukushima Daiichi Nuclear Power Plant accident occurred. It is a "coincidence of global history" that it now coincides with the starting point of the 100% renewable energy initiative that is accelerating around the world.

The world has changed dramatically since 311. Germany, Italy, Switzerland, Taiwan, South Korea, China and many other countries were all shocked by 311 and shifted their focus from nuclear power to renewable energy, and in the U.S. clean energy industries are setting sights on market majority to accelerate this trend. The next ten years will be the decade in which this perception will rapidly become the "new reality". 311 was the "starting point" for a structural energy shift in world history.

Hans-Josef Fell, former MP, President of the Energy Watch Group and co-initiator of the Global100RE Strategy Group:

The disasters of Fukushima and Chernobyl are urging the entire world to quickly end the use of atomic energy, and many call for a fossil fuel lockdown to catalyze a climate revolution alongside the transition. Contrary to what is often claimed, nuclear energy cannot make a contribution to climate protection, but only creates immense problems with toxic radioactivity emissions, nuclear waste, atomic bomb material and the dangers of a nuclear catastrophe. In contrast, 100% renewable energies until 2030 can help achieve climate protection and a simultaneous nuclear phase-out, according to a recently published statement by a world-leading group of energy researchers from the USA, EU and Australia.

Their research suggests that a 100% renewable energy supply, including storage systems, can provide full energy security for all of mankind by 2030 and will even be cheaper than the existing nuclear and fossil energy supply, and with over 30% of global electricity already from renewables, momentum is strong. The only requirement for implementation is the right decisions taken by decision makers both in governments and industry. All technical and economic prerequisites for a disruptive conversion of the global energy supply to 100% renewable energies are already in place.

Hon. Peter Rae AO, President of WWEA and Honorary Chairman of the REN Alliance:

40 years ago, the idea of developing nuclear power appealed to me as a non-polluting method of generating electricity. So I studied it. How to deal with waste and how to ensure it would not create a danger to life. Along came Chernobyl and other accidents. Storage of waste was leaving dangerous hiding places while some waste was alleged to be dumped at sea. I became more and more concerned. There were demonstrations that the existing methods were dangerous and required very strict construction and operational tolerances - up went the cost. Long delays and huge cost increases. I had visited nuclear power stations and talked to expert proponents in UK, France, US, Taiwan and Australia, and debates such as New Zealand's electricity future reflect similar concerns. The more I did the more certain I became that it was not the way to go. Then Fukushima put the dangers and cost beyond doubt.

Let's get on with the rollover to renewables.

Dr. Marit Brommer, Executive Director of the International Geothermal Association IGA:

The IGA is proud to work with all renewable energy associations to continuously provide a unified voice to a cleaner energy future. The Geothermal sector is proven to be a partner of choice for many locations in the world serving baseload power and clean heat to customers. We are particularly interested in the increased attention system integration gets, which underpins the importance of all renewables coming together at events such as the webinar organised by the WWEA.

Christian Rakos, President of the World Bioenergy Association:

The IPCC has emphasized the important role of sustainable bioenergy for climate protection. Recent advances in technology allow us to use feedstock from forestry, wood processing and agricultural production in an efficient and clean way. Today, bioenergy already contributes 12 - 13% to global final energy demand. Importantly, contribution from bioenergy is more than 5 times as much as nuclear energy worldwide. Together with other renewable energy technologies such as solar, wind, geothermal and hydropower, bioenergy can increase the contribution in a substantial way to meet the energy demands of all end use sectors and meet the international energy and climate goals.

Stefan Gsanger, Secretary General of the World Wind Energy Association and Co-chair of the Global100RE Platform:

The switch to a renewable energy future requires new political and economic thinking: from centralised structures with few large actors towards decentralised, participatory models with millions of communities and citizens playing an active role, not only as consumers but also as producers of energy. To make this new paradigm the predominant energy paradigm is the true challenge of the energy transformation which we as the world community are facing. If we manage this shift well and on time, billions of people across the globe, in industrialised and developing countries alike, will benefit and will face a bright future.

 

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Elon Musk says cheaper, more powerful electric vehicle batteries are 3 years off

Tesla Battery Day Innovations detail larger cylindrical EV cells with higher energy density, greater power, longer range, cobalt-free chemistry, automated manufacturing, battery recycling, and lower cost per kWh to enable an affordable electric car.

 

Key Points

Tesla Battery Day innovations are new EV cells and methods to cut costs, extend range, and scale production.

✅ Larger cylindrical cells: 5x energy, 6x power, 16% more range

✅ Automation and recycling to cut battery cost per kWh

✅ Near-zero cobalt chemistry, in-house cell factories worldwide

 

Elon Musk described a new generation of electric vehicle batteries that will be more powerful, longer lasting, and half as expensive as the company’s current cells at Tesla’s “Battery Day”.

Tesla’s new larger cylindrical cells will provide five times more energy, six times more power and 16% greater driving range, Musk said, adding that full production is about three years away.

“We do not have an affordable car. That’s something we will have in the future. But we’ve got to get the cost of batteries down,” Musk said.

To help reduce cost, Musk said Tesla planned to recycle battery cells at its Nevada “gigafactory,” while reducing cobalt – one of the most expensive battery materials – to virtually zero. It also plans to manufacture its own battery cells at several highly automated factories around the world.

The automaker plans to produce the new cells via a highly automated, continuous-motion assembly process, according to Drew Baglino, Tesla senior vice-president of powertrain and energy engineering, a contrast with GM and Ford battery strategies in the broader market today.

Speaking at the event, during which Musk outlined plans to cut costs and reiterated a huge future for Tesla's energy business during the presentation, the CEO acknowledged that Tesla does not have its new battery design and manufacturing process fully complete.

The automaker’s shares slipped as Musk forecast the change could take three years. Tesla has frequently missed production targets.

Tesla expects to eventually be able to build as many as 20m electric vehicles a year, aligning with within-a-decade EV adoption outlooks cited by analysts. This year, the entire auto industry expects to deliver 80m cars globally.

At the opening of the event, which drew over 270,000 online viewers, Musk walked on stage as about 240 shareholders – each sitting in a Tesla Model 3 in the company parking lot – honked their car horns in approval.

As automakers shift from horsepower to kilowatts to comply with stricter environmental regulations amid an age of electric cars that appears ahead of schedule, investors are looking for evidence that Tesla can increase its lead in electrification technology over legacy automakers who generate most of their sales and profits from combustion-engine vehicles.

While average electric vehicle prices have decreased in recent years thanks to changes in battery composition and evidence that they are better for the planet and household budgets, they are still more expensive than conventional cars, with the battery estimated to make up a quarter to a third of an electric vehicle’s cost.

Some researchers estimate that price parity, or the point at which electric vehicles are equal in value to internal combustion cars, is reached when battery packs cost $100 per kilowatt hour (kWh), a potential inflection point for mass adoption.

Tesla’s battery packs cost $156 per kWh in 2019, according to electric vehicle consulting firm Cairn Energy Research Advisors, with some studies noting that EVs save money over time for consumers, which would put the cost of a 90-kWh pack at around $14,000.

Tesla is also building its own cell manufacturing facility at its new factory in Germany in addition to the new plant in Fremont.

 

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The Age of Electric Cars Is Dawning Ahead of Schedule

EV Price Parity is nearing reality in Europe as subsidies, falling battery costs, higher energy density, and expanding charging infrastructure push Tesla, Volkswagen, and Renault to compete under EU CO2 regulations and fleet targets.

 

Key Points

EV price parity means EVs match ICE cars on total ownership cost as subsidies fade and batteries get cheaper.

✅ Battery pack costs trending toward $100/kWh

✅ EU CO2 rules and incentives accelerate adoption

✅ Charging networks reduce range anxiety and TCO

 

An electric Volkswagen ID.3 for the same price as a Golf. A Tesla Model 3 that costs as much as a BMW 3 Series. A Renault Zoe electric subcompact whose monthly lease payment might equal a nice dinner for two in Paris.

As car sales collapsed in Europe because of the pandemic, one category grew rapidly: electric vehicles, a shift that some analysts say could put most drivers within a decade on battery power. One reason is that purchase prices in Europe are coming tantalizingly close to the prices for cars with gasoline or diesel engines.

At the moment this near parity is possible only with government subsidies that, depending on the country, can cut more than $10,000 from the final price. Carmakers are offering deals on electric cars to meet stricter European Union regulations on carbon dioxide emissions. In Germany, an electric Renault Zoe can be leased for 139 euros a month, or $164.

Electric vehicles are not yet as popular in the United States, largely because government incentives are less generous, but an emerging American EV boom could change that trajectory. Battery-powered cars account for about 2 percent of new car sales in America, while in Europe the market share is approaching 5 percent. Including hybrids, the share rises to nearly 9 percent in Europe, according to Matthias Schmidt, an independent analyst in Berlin.

As electric cars become more mainstream, the automobile industry is rapidly approaching the tipping point, an inflection point for the market, when, even without subsidies, it will be as cheap, and maybe cheaper, to own a plug-in vehicle than one that burns fossil fuels. The carmaker that reaches price parity first may be positioned to dominate the segment.

A few years ago, industry experts expected 2025 would be the turning point. But technology is advancing faster than expected, and could be poised for a quantum leap. Elon Musk is expected to announce a breakthrough at Tesla’s “Battery Day” event on Tuesday that would allow electric cars to travel significantly farther without adding weight.

The balance of power in the auto industry may depend on which carmaker, electronics company or start-up succeeds in squeezing the most power per pound into a battery, what’s known as energy density. A battery with high energy density is inherently cheaper because it requires fewer raw materials and less weight to deliver the same range.

“We’re seeing energy density increase faster than ever before,” said Milan Thakore, a senior research analyst at Wood Mackenzie, an energy consultant which recently pushed its prediction of the tipping point ahead by a year, to 2024.

Some industry experts are even more bullish. Hui Zhang, managing director in Germany of NIO, a Chinese electric carmaker with global ambitions, said he thought parity could be achieved in 2023.

Venkat Viswanathan, an associate professor at Carnegie Mellon University who closely follows the industry, is more cautious, though EV revolution skeptics argue the revolution is overstated. But he said: “We are already on a very accelerated timeline. If you asked anyone in 2010 whether we would have price parity by 2025, they would have said that was impossible.”

This transition will probably arrive at different times for different segments of the market. High-end electric vehicles are pretty close to parity already. The Tesla Model 3 and the gas-powered BMW 3 Series both sell for about $41,000 in the United States.

A Tesla may even be cheaper to own than a BMW because it never needs oil changes or new spark plugs and electricity is cheaper, per mile, than gasoline. Which car a customer chooses is more a matter of preference, particularly whether an owner is willing to trade the convenience of gas stations for charging points that take more time. (On the other hand, owners can also charge their Teslas at home.)

Consumers tend to focus on sticker prices, and it will take longer before unsubsidized electric cars cost as little to drive off a dealer’s lot as an economy car, even for shoppers weighing whether it’s the right time to buy an electric car now.

The race to build a better battery
The holy grail in the electric vehicle industry has been to push the cost of battery packs — the rechargeable system that stores energy — below $100 per kilowatt-hour, the standard measure of battery power. That is the point, more or less, at which propelling a vehicle with electricity will be as cheap as it is with gasoline.

Current battery packs cost around $150 to $200 per kilowatt-hour, depending on the technology. That means a battery pack costs around $20,000. But the price has dropped 80 percent since 2008, according to the United States Department of Energy.

All electric cars use lithium-ion batteries, but there are many variations on that basic chemistry, and intense competition to find the combination of materials that stores the most power for the least weight.

For traditional car companies, this is all very scary. Internal combustion engines have not changed fundamentally for decades, but battery technology is still wide open. There are even geopolitical implications. China is pouring resources into battery research, seeing the shift to electric power as a chance for companies like NIO to make their move on Europe and someday, American, markets. In less than a decade, the Chinese battery maker CATL has become one of the world’s biggest manufacturers.


Everyone is trying to catch Tesla
The California company has been selling electric cars since 2008 and can draw on years of data to calculate how far it can safely push a battery’s performance without causing overheating or excessive wear. That knowledge allows Tesla to offer better range than competitors who have to be more careful. Tesla’s four models are the only widely available electric cars that can go more than 300 miles on a charge, according to Kelley Blue Book.

On Tuesday, Mr. Musk could unveil a technology offering 50 percent more storage per pound at lower cost, according to analysts at the Swiss bank UBS. If so, competitors could recede even further in the rearview mirror.

“The traditional car industry is still behind,” said Peter Carlsson, who ran Tesla’s supplier network in the company’s early days and is now chief executive of Northvolt, a new Swedish company that has contracts to manufacture batteries for Volkswagen and BMW.

“But,” Mr. Carlsson said, “there is a massive amount of resources going into the race to beat Tesla. A number, not all, of the big carmakers are going to catch up.”

The traditional carmakers’ best hope to avoid oblivion will be to exploit their expertise in supply chains and mass production to churn out economical electrical cars by the millions.

A key test of the traditional automakers’ ability to survive will be Volkswagen’s new battery-powered ID.3, which will start at under €30,000, or $35,000, after subsidies and is arriving at European dealerships now. By using its global manufacturing and sales network, Volkswagen hopes to sell electric vehicles by the millions within a few years. It plans to begin selling the ID.4, an electric sport utility vehicle, in the United States next year. (ID stands for “intelligent design.”)

But there is a steep learning curve.

“We have been mass-producing internal combustion vehicles since Henry Ford. We don’t have that for battery vehicles. It’s a very new technology,” said Jürgen Fleischer, a professor at the Karlsruhe Institute of Technology in southwestern Germany whose research focuses on battery manufacturing. “The question will be how fast can we can get through this learning curve?”

It’s not just about the batteries
Peter Rawlinson, who led design of the Tesla Model S and is now chief executive of the electric car start-up Lucid, likes to wow audiences by showing up at events dragging a rolling carry-on bag containing the company’s supercompact drive unit. Electric motor, transmission and differential in one, the unit saves space and, along with hundreds of other weight-saving tweaks, will allow the company’s Lucid Air luxury car — which the company unveiled on Sept. 9 — to travel more than 400 miles on a charge, Mr. Rawlinson said.

His point is that designers should focus on things like aerodynamic drag and weight to avoid the need for big, expensive batteries in the first place. “There is kind of a myopia,” Mr. Rawlinson said. “Everyone is talking about batteries. It’s the whole system.”

“We have been mass-producing internal combustion vehicles since Henry Ford,” said Jürgen Fleischer, a professor at the Karlsruhe Institute of Technology. “We don’t have that for battery vehicles.”

A charger on every corner would help
When Jana Höffner bought an electric Renault Zoe in 2013, driving anywhere outside her home in Stuttgart was an adventure. Charging stations were rare, and didn’t always work. Ms. Höffner drove her Zoe to places like Norway or Sicily just to see if she could make it without having to call for a tow.

Ms. Höffner, who works in online communication for the state of Baden-Württemberg, has since traded up to a Tesla Model 3 equipped with software that guides her to the company’s own network of chargers, which can fill the battery to 80 percent capacity in about half an hour. She sounds almost nostalgic when she remembers how hard it was to recharge back in the electric-vehicle stone age.

“Now, it’s boring,” Ms. Höffner said. “You say where you want to go and the car takes care of the rest.”

The European Union has nearly 200,000 chargers, far short of the three million that will be needed when electric cars become ubiquitous, according to Transport & Environment, an advocacy group. The United States remains far behind, with less than half as many as Europe, even as charging networks jostle under federal electrification efforts.

But the European network is already dense enough that owning and charging an electric car is “no problem,” said Ms. Höffner, who can’t charge at home and depends on public infrastructure.
 

 

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