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

Tesla Q2 2020 earnings highlight resilient electric vehicles as production and deliveries outpace legacy automakers, while Gigafactory Austin advances, solar installations slump, and energy storage, Megapack, and free cash flow expand despite COVID-19 disruptions.

Key Points

Tesla posted a fourth consecutive profit, strong cash, EV resilience, solar slump, and rising energy storage.

✅ Fourth straight profit and $418M free cash flow

✅ EV output and deliveries fell just 5% year over year

✅ Solar hit record low; storage rose 61% to 419 MWh

Tesla survived the throes of the coronavirus pandemic relatively unscathed, chalking up its fourth sequential quarterly profit for the first time on Wednesday.

On the energy front, however, things were much more complicated: Tesla reported its worst-ever quarter for solar installations but huge growth in its battery business, amid expectations for cheaper, more powerful batteries expected in coming years. CEO Elon Musk nevertheless predicted the energy business will one day rival its car division in scale.

But today, Tesla's bottom line is all about electric vehicles, and the temporary halt of activity at Tesla's Fremont factory due to local health orders didn’t put much of a dent in vehicle production and delivery. Both figures declined 5 percent compared to the same quarter in 2019. In contrast, Q2 vehicle sales at legacy carmakers Ford, GM and Fiat Chrysler declined by one-third or more year-over-year, even as the U.S. EV market share dipped in early 2024 for context.

The costs of factory closures and a $101 million CEO award milestone for Elon Musk didn’t stop Tesla from achieving $418 million in free cash flow, a major improvement over the prior quarter. Cash and cash equivalents grew by $535 million to $8.6 billion during the quarter.

Musk praised his employees for “exceptional execution.” 

“There were so many challenges, too numerous to name, but they got it done,” he said on an investor call Wednesday.

Musk also confirmed that Tesla will build a new Gigafactory in Austin, Texas, five minutes from the airport. The 2,000-acre campus will abut the Colorado River and is “basically going to be an ecological paradise,” he said. The new Texas factory will build the Cybertruck, Semi, Model 3 and Model Y for the Eastern half of North America. Fremont, California will produce the S and X, and make Model 3 and Model Y for the West, in a state where EVs exceed 20% of sales according to recent data.

Return of the Tesla solar slump

This was the first entire quarter affected by the coronavirus response, which threw the rooftop solar industry into turmoil by cutting off in-person sales. Other installers scrambled to shift to digital-first sales strategies, but Tesla had already done so months before lockdowns were imposed.

Q2, then, offers a test case on whether Tesla’s pivot to passive online sales made it better able to deal with stay-at-home orders than its peers. The other publicly traded solar installers have not yet reported their Q2 performance, but Tesla delivered its worst-ever quarterly solar figures: Installations totaled just 27 megawatts. That’s a 7 percent decline from Q2 2019, its previous worst quarter ever for solar.

Musk did not address that weak performance in his remarks to investors, opting instead to highlight the company’s late-June decision to offer the cheapest solar pricing in the country. “We’re the company to go to,” he said of rooftop solar. “It’s only going to get better later this year.”

But the sales slump indicates Tesla’s online sales model could not withstand a historically tough season for residential solar.

"Every single residential installer in the country is going to have a bad Q2 because of the initial impacts of COVID on the market," said Austin Perea, senior solar analyst at Wood Mackenzie. "It's hard to disaggregate the impacts of COVID from their own individual strategies."

Tesla's 23 percent decline in quarter-over-quarter solar installations was not as bad as the expected Q2 decline across the rooftop solar industry, Perea added.

On the vehicle side, Tesla’s sales declined less than did those of major automakers. It’s possible that the same pattern will hold for solar; a less severe drop than those seen by Sunrun or Vivint could be claimed as a victory of sorts. But this quarter made clear that Q2 2019 was not the bottom for Tesla’s solar operation, which once led the residential market as SolarCity but significantly diminished since Tesla acquired it in 2016.

Tesla currently stands in third place for residential solar installers. But No. 1 installer Sunrun said this month that it will acquire No. 2 installer Vivint Solar, making Tesla the second-largest installer by default. That major consolidation in the rooftop solar market went unremarked upon in Tesla's investor call.

Solar and energy storage revenue currently equate to just 7 percent of the company's automotive revenue. But Musk reiterated his prediction that this won’t always be the case. “Long term, Tesla Energy will be roughly the same size as Tesla Automotive,” he said on Wednesday's call.

The grid storage business offered more reason for optimism: Capacity deployed grew 61 percent from the first quarter, rising to 419 megawatt-hours. The prepackaged, large-format Megapack product turned its first profit that quarter.

"Difficult to predict" performance in the second half of 2020
Tesla withdrew its financial guidance last quarter in light of the upheaval across the global economy. It refrained from setting new guidance now.

“Although we have successfully ramped vehicle production back to prior levels, it remains difficult to predict whether there will be further operational interruptions or how global consumer sentiment will evolve, given risks to the EV boom noted by analysts, in the second half of 2020,” the earnings report notes.

The company asserted it will still deliver 500,000 vehicles this year regardless of externalities, a goal that aligns with broader EV sales momentum in 2024 trends. It already has sufficient production capacity installed to reach that, Tesla said. But with 179,387 cars delivered so far, Tesla faces an uphill climb to ship more cars in the second half.

Wall Street maintained its buoyant confidence in Tesla's share price, despite rising competition in China noted by rivals. It closed at $1,592 before the earnings announcement, rising to $1,661 in after-hours trading.

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Green Hydrogen for Steelmaking enables decarbonization in Germany by powering electrolyzers with wind turbines at Salzgitter. Partners Vestas, Avacon, and Linde support renewable hydrogen for iron ore reduction, cutting CO2 in heavy industry.

Key Points

Hydrogen from renewable-powered electrolysis replacing coal in iron ore reduction, cutting CO2 emissions from steelmaking

✅ 30 MW Vestas wind farm powers 2x1.25 MW electrolyzers.

✅ Salzgitter, Avacon, Linde link sectors to replace fossil fuels.

✅ Targets CO2 cuts in iron ore reduction and steel smelting.

A major green hydrogen facility in Germany has started operations, with those behind the project hoping it will help to decarbonize the energy-intensive steel industry in the years ahead. 

The "WindH2" project involves German steel giant Salzgitter, E.ON subsidiary Avacon and Linde, a firm specializing in engineering and industrial gases, and aligns with calls for hydrogen-ready power plants in Germany today.

Hydrogen can be produced in a number of ways. One method includes using electrolysis, with an electric current splitting water into oxygen and hydrogen, and advances in PEM hydrogen technology continue to improve efficiency worldwide.

If the electricity used in the process comes from a renewable source such as wind or solar, as underscored by recent German renewables gains, then it's termed "green" or "renewable" hydrogen.

The development in Germany is centered around seven new wind turbines operated by Avacon and two 1.25 megawatt (MW) electrolyzer units installed by Salzgitter Flachstahl, which is part of the wider Salzgitter Group. The facilities were presented to the public this week. 

The turbines, from Vestas, have a hub height of 169 meters and a combined capacity of 30 MW. All are located on premises of the Salzgitter Group, with three situated on the site of a steel mill in the city of Salzgitter, Lower Saxony, northwest Germany, where grid expansion woes can affect project timelines.

The hydrogen produced using renewables will be utilized in processes connected to the smelting of iron ore. Total costs for the project come to roughly 50 million euros (around $59.67 million), with the building of the electrolyzers subsidized by state-owned KfW, while a national net-zero roadmap could reduce electricity costs over time.

"Green gases have the wherewithal to become 'staple foodstuff' for the transition to alternative energies and make a considerable contribution to decarbonizing industry, mobility and heat," E.ON's CEO, Johannes Teyssen, said in a statement issued Thursday.

"The jointly realized project symbolizes a milestone on the path to virtually CO2 free production and demonstrates that fossil fuels can be replaced by intelligent cross-sector linking," he added.

According to the International Energy Agency, the iron and steel sector is responsible for 2.6 gigatonnes of direct carbon dioxide emissions each year, a figure that, in 2019, was greater than the direct emissions from sectors such as cement and chemicals. 

It adds that the steel sector is "the largest industrial consumer of coal, which provides around 75% of its energy demand."

The project in Germany is not unique in focusing on the role green hydrogen could play in steel manufacturing.

Across Europe, projects are also exploring natural gas pipe storage to balance intermittent renewables and enable sector coupling.

H2 Green Steel, a Swedish firm backed by investors including Spotify founder Daniel Ek, plans to build a steel production facility in the north of the country that will be powered by what it describes as "the world's largest green hydrogen plant."

In an announcement last month the company said steel production would start in 2024 and be based in Sweden's Norrbotten region.

Other energy-intensive industries are also looking into the potential of green hydrogen, and examples such as Schott's green power shift show parallel decarbonization. A subsidiary of multinational building materials firm HeidelbergCement has, for example, worked with researchers from Swansea University to install and operate a green hydrogen demonstration unit at a site in the U.K.

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Canada Electricity Decarbonization Costs indicate challenging greenhouse gas reductions across a fragmented grid, with wind, solar, nuclear, and natural gas tradeoffs, significant GDP impacts, and Net Zero targets constrained by intermittency and limited interties.

Key Points

Costs to cut power CO2 via wind, solar, gas, and nuclear, considering grid limits, intermittency, and GDP impacts.

✅ Alberta model: eliminate coal; add wind, solar, gas; 26-40% CO2 cuts

✅ Nuclear option enables >75% cuts at higher but feasible system costs

✅ National costs 1-2% GDP; reserves, transmission, land, and waste not included

Along with many western developed countries, Canada has pledged to reduce its greenhouse gas emissions by 40–45 percent by 2030 from 2005 emissions levels, and to achieve net-zero emissions by 2050.

This is a huge challenge that, when considered on a global scale, will do little to stop climate change because emissions by developing countries are rising faster than emissions are being reduced in developed countries. Even so, the potential for achieving emissions reduction targets is extremely challenging as there are questions as to how and whether targets can be met and at what cost. Because electricity can be produced from any source of energy, including wind, solar, geothermal, tidal, and any combustible material, climate change policies have focused especially on nations’ electricity grids, and in Canada cleaning up electricity is viewed as critical to meeting climate pledges.

Canada’s electricity grid consists of ten separate provincial grids that are weakly connected by transmission interties to adjacent grids and, in some cases, to electricity systems in the United States. At times, these interties are helpful in addressing small imbalances between electricity supply and demand so as to prevent brownouts or even blackouts, and are a source of export revenue for provinces that have abundant hydroelectricity, such as British Columbia, Manitoba, and Quebec.

Due to generally low intertie capacities between provinces, electricity trade is generally a very small proportion of total generation, though electricity has been a national climate success in recent years. Essentially, provincial grids are stand alone, generating electricity to meet domestic demand (known as load) from the lowest cost local resources.

Because climate change policies have focused on electricity (viz., wind and solar energy, electric vehicles), and Canada will need more electricity to hit net-zero according to the IEA, this study employs information from the Alberta electricity system to provide an estimate of the possible costs of reducing national CO2 emissions related to power generation. The Alberta system serves as an excellent case study for examining the potential for eliminating fossil-fuel generation because of its large coal fleet, favourable solar irradiance, exceptional wind regimes, and potential for utilizing BC’s reservoirs for storage.

Using a model of the Alberta electricity system, we find that it is infeasible to rely solely on renewable sources of energy for 100 percent of power generation—the costs are prohibitive. Under perfect conditions, however, CO2 emissions from the Alberta grid can be reduced by 26 to 40 percent by eliminating coal and replacing it with renewable energy such as wind and solar, and gas, but by more than 75 percent if nuclear power is permitted. The associated costs are estimated to be some $1.4 billion per year to reduce emissions by at most 40 percent, or $1.9 billion annually to reduce emissions by 75 percent or more using nuclear power (an option not considered feasible at this time).

Based on cost estimates from Alberta, and Ontario’s experience with subsidies to renewable energy, and warnings that the switch from fossil fuels to electricity could cost about $1.4 trillion, the costs of relying on changes to electricity generation (essentially eliminating coal and replacing it with renewable energy sources and gas) to reduce national CO2 emissions by about 7.4 percent range from some $16.8 to $33.7 billion annually. This constitutes some 1–2 percent of Canada’s GDP.

The national estimates provided here are conservative, however. They are based on removing coal-fired power from power grids throughout Canada. We could not account for scenarios where the scale of intermittency turned out worse than indicated in our dataset—available wind and solar energy might be lower than indicated by the available data. To take this into account, a reserve market is required, but the costs of operating such a capacity market were not included in the estimates provided in this study. Also ignored are the costs associated with the value of land in other alternative uses, the need for added transmission lines, environmental and human health costs, and the life-cycle costs of using intermittent renewable sources of energy, including costs related to the disposal of hazardous wastes from solar panels and wind turbines.

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Hydrogen vs Battery-Electric Vehicles compare FCEV and BEV tech for range, charging and refueling, zero-emissions, infrastructure in Canada, highlighting urban commuting, heavy-duty use, fast 5-minute fills, 30-minute fast charging, and renewable hydrogen from surplus wind.

Key Points

Hydrogen FCEVs suit long range and heavy-duty use; BEVs excel in urban commutes with overnight charging.

✅ FCEVs refuel in about 5 minutes; ideal for long range and heavy duty.

✅ BEVs fit urban commuting with home or night charging; fewer stops.

✅ Hydrogen enables energy storage from surplus wind and hydro power.

We’re constantly hearing that battery-electric cars are the future, as automakers pursue Canada-U.S. collaboration on EVs across the industry, so I was surprised to see that companies like Toyota, Honda and Hyundai are making hydrogen fuel-cell cars. Which technology is better? Could hydrogen still win? – Pete, Kingston

They’re both in their electric youth, relatively speaking, but the ultimate winner in the race between hydrogen and battery electric will likely be both.

“It’s not really a competition – they’ll both co-exist and there will also be plug-in hydrogen hybrids,” said Walter Merida, director of the Clean Energy Research Centre at the University of British Columbia. “Battery-electric vehicles [BEVs] are better for an urban environment where you have time to recharge and fuel-cell electric vehicles [FCEVs] are better-suited for long range and heavy duty.”

Last year, there were 9,840 BEVs sold in Canada, up from 5,130 the year before. If you include plug-in hybrids, the number sold in 2017 grows to 18,560, though many buyers now face EV shortages and wait times amid high gasoline prices.

And how many hydrogen vehicles were sold in Canada last year?

#google#

None – although Hyundai leased out about a half-dozen hydrogen Tucsons in British Columbia for $599 a month, which included fuel from Powertech labs in Surrey.

In January, Toyota announced it will be selling the Mirai in Quebec later this year. And Hyundai said it will offer about 25 Nexos for sale.

“It’s chicken or egg,” said Michael Fowler, a professor of chemical engineering at the University of Waterloo. “Car manufacturers won’t release cars into the market unless there’s a refuelling station and companies won’t build a refuelling station unless there are cars to fuel.”

Right now, there are no retail hydrogen refuelling stations in Canada. While there are plans under way to add stations in B.C., Ontario and Quebec, we’re still behind Japan, Europe and California, though experts outline how Canada can capitalize on the U.S. EV pivot to accelerate progress.

“In 2007, Ontario had a hydrogen strategy and they were starting to develop hydrogen vehicles and they dropped that in favour of the Green Energy Act and it was a complete disaster,” Fowler said. “The reality is the government of the day listened to the wrong people.”

It’s tough to pinpoint a single reason why governments focused on building charging stations instead of hydrogen stations, Merida said.

“It’s ironic, you know – the fuel cell was invented in Vancouver. Geoffrey Ballard was one of the pioneers of this technology,” Merida said. “And for a while, Canada was a global leader, but eventually government programs were discontinued and that was very disruptive to the sector.”

HYDROGEN FOR THE MASSES?

While we tend to think of BEVs when we think of electric cars, fuel-cell vehicles are electric, too; the hydrogen passes through a fuel cell stack, where it mixes with oxygen from the atmosphere to produce an electric current.

That current powers electric motors to drive the wheels and extra energy goes to a battery pack that’s used to boost acceleration (it’s also charged by regenerative braking).

Except for water that drips out of the hydrogen car, they’re both zero-emission on the road.

But a big advantage for hydrogen is that, if you can find a station, you can pull up to a pump and fill up in five minutes or less – the same way we do now at nearly 12,000 gas stations.

Compare that with fast-charging stations that can charge a battery to 80 per cent in 30 minutes – each station only handles one car at a time. What if you get there and it’s busy – or broken? And right now, there are only 139 of them in Canada.

And at slower, Level 2 stations, cars have to be plugged in for hours to recharge.

In a 2018 KPMG survey of auto executives, 55 per cent said that moves to switch entirely to pure battery-electric vehicles will fail because there won’t be enough charging stations, and some critics argue the 2035 EV mandate is delusional given infrastructure constraints.

“Ontario just invested $20-million in public charging stations and that’s going to service 100 or 200 cars a day,” Fowler said. “If you were to invest that in hydrogen stations, you’d be able to service thousands of cars a day.”

And when you do charge at a station, you might not be using clean power, as 18% of Canada’s 2019 electricity came from fossil fuels according to national data, Fowler said.

“At least in Ontario, in order to charge at a public station during the day, you have to rev up a natural-gas plant somewhere,” Fowler said. “So the only way you’re getting zero emissions is when you can charge at night using excess nuclear, hydro or wind that’s not being used.”

But hydrogen can be made when surplus green energy is stored, Fowler said.

“In Ontario, we have lots of wind in the spring and the fall, when we don’t need the electricity,” he said.

And eventually, you’ll be able to connect your fuel-cell vehicle to the grid and sell the power it produces, Merida said.

“The amount of power generation you have in these moving platforms is quite significant,” Merida said.

There are other strikes against battery-electric, including reduced range by 30 per cent or more in the winter and the need to upgrade infrastructure such as electrical transformers so they can handle more than just a handful of cars on each street charging at night, Fowler said.

In that KPMG survey, executives predicted a nearly equal split between BEVs, FCEVs, hybrids and gasoline engines by 2040.

“Battery-electric vehicles will serve a certain niche – they’ll be small commuter vehicles in certain cities,” Fowler said. “But for the way we use cars today – the family car, the suburban car, buses and probably trucks – it will be the fuel cell.”

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Newfoundland EV Fast-Charging Network enables DC fast charging along the Trans-Canada Highway, from Port aux Basques to St. John's, with Level 3 stations, reducing range anxiety and accelerating electric vehicle adoption.

Key Points

A DC fast charging corridor with Level 3 stations every 70 km, enabling EV road trips and easing range anxiety.

✅ 14 Level 3 DC fast chargers across the Trans-Canada Highway

✅ Charges most EVs to 80% in under an hour, $15/hr prorated

✅ Expansion planned into Labrador with 19 additional fast chargers

The first electric vehicle fast-charging network is now up and running across Newfoundland, which the province's main energy provider hopes will make road trips easier for electric car owners and encourage more drivers to go electric in the future.

With the last of the 14 charging stations coming online in Corner Brook earlier this month, drivers now have a place to charge up about every 70 kilometres along the Trans-Canada Highway, where 10 new fast-charging stations in N.B. are being planned, from Port aux Basques to St. John's, along with one in Gros Morne National Park.

Jennifer Williams, president & CEO of Newfoundland and Labrador Hydro, says many potential electric vehicle owners have been hesitant to give up on gasoline without fast chargers available across the island.

"The majority of people who were interested in EVs said one of the major barriers to them was indeed not having a fast-charging network that they could access," she said.

"We really believe that this is going to help people cross over and become an EV owner."

The charging network was first announced in October 2019, with an eye to having all 14 chargers up and running by the end of 2020. When work began, Newfoundland and Labrador was the only province in Canada without any publicly available Level 3 chargers, even as NB Power's public charging network was expanding elsewhere.

After some COVID-19 pandemic-related delays, the stations are now up and running and can charge most EVs to 80 per cent in less than an hour at a prorated cost of $15 an hour

"The pandemic did have some effect, but we're there now and we're really happy and this is just the beginning," said Williams.

Public charging becoming 'a non-issue'
That's encouraging for Jon Seary, an electric car owner and a co-founder of advocacy group Drive Electric N.L. He says the lack of fast chargers has been the "deal breaker" for many people looking to buy electric vehicles.

"Now you can drive right across the province. You can choose to stop at any of these to top up," Seary said.

Joe Butler, who is also a co-founder of the group, says the fast chargers have already made trips easier as they've come online across the island.

"In the past, it was a major impediment, really, to get anywhere, but now it's changed dramatically," said Butler.

"I just came back from Gros Morne and I had two stops and I was home, so the convenience factor if you just travel occasionally outside of town makes all the difference."

Jon Seary and Joe Butler stand with a slower level-two charging station on Kenmount Road in St. John's. 'We are at the cusp now of seeing a huge upswing in electric vehicle adoption,' Seary said. (Gavin Simms/CBC)
Seary said according to numbers from provincial motor vehicle registration, there were 195 electric cars on the road at the end of 2020, but he estimates that there are now closer to 300 vehicles in use in the province — with the potential for many more.

"We are at the cusp now of seeing a huge upswing in electric vehicle adoption," he said, even though Atlantic Canadians have been less inclined to buy EVs so far. 

"The cost of the cars is coming way down, and has come down. More places are selling them and the availability of public charging is becoming a non-issue as we put more and more charging stations out there."

The future is electric but the province's infrastructure is lagging behind, says non-profit
But Seary said there is still more work to be done to improve the province's charging infrastructure to catch up with other parts of the country. 

"We are lagging the rest of the country," Seary said, even as the N.W.T. encourages more residents to drive EVs through new initiatives.

"We have opportunities for federal funding for our charging infrastructure and it needs to be moving now. We have the surplus from Muskrat Falls to use and we have a climate that's not going to wait … this is the time to get going with this now."

Williams said together with Newfoundland Power, N.L. Hydro is now working on 19 more fast chargers to be placed elsewhere in the province and into Labrador, where the N.L. government has promoted EV adoption but infrastructure has lagged in some areas.

"We've heard very loudly and very clearly from the folks in Labrador, as well as other parts of the province, that they want to have charging stations in their neck of the woods too," she said.

"Putting them in Labrador, we believe that we'll help people get over that concern and that fear. There are EV owners in Labrador … so we believe it can work there as well."

With more chargers and electric vehicles comes less reliance on burning fossil fuels, and utilities like Nova Scotia Power are piloting vehicle-to-grid integration to amplify benefits, and Williams said 21 tonnes of greenhouse gas emissions have already been offset with the chargers as they've come online over the past few months.

"It actually does equate to as if you had powered a whole house all year, but the important part to remember [is that] these are an enabler. Putting these in place is enabling people to purchase electric vehicles," she said.

"You do 90 per cent of your charging at home, so if we're seeing about 20 tonnes has been offset in the short period of time they've been in service, for the vehicles that are charging at home, imagine how much they're actually offsetting. We figure it's well in excess of 200 tons."

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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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