UK to fast-track vital grid connections

EV battery supply strategies weigh in-house cell manufacturing against supplier contracts, optimizing costs, scale, and supply-chain resilience for electric vehicles. Automakers like Tesla, GM-LG Chem, VW-Northvolt, and Ford balance gigafactories, joint ventures, and procurement risks.

Key Points

How automakers secure EV battery cells by balancing cost, scale, tech risk, and supply-chain control to meet demand.

✅ In-source cells via gigafactories, JVs, and proprietary chemistries

✅ Contract with LG Chem, Panasonic, CATL, SKI to diversify supply

✅ Manage costs, logistics, IP, and technology obsolescence risks

Auto makers, pumping billions of dollars into developing electric cars, are now facing a critical inflection point as they decide whether to get more involved with manufacturing the core batteries or buy them from others.

Batteries are one of an electric vehicle’s most expensive components, accounting for between a quarter and a third of the car’s value. Driving down their cost is key to profitability, executives say.

But whereas the internal combustion engine traditionally has been engineered and built by auto makers themselves, battery production for electric cars is dominated by Asian electronics and chemical firms, such as LG Chem Ltd. and Panasonic Corp. , and newcomers like China’s Contemporary Amperex Technology Co.

California, the U.S.’s largest car market, said last month it would end the sale of new gasoline- and diesel-powered passenger cars by 2035, putting pressure on the auto industry to accelerate its shift to electric vehicles in the coming years.

The race to lock in supplies for electric cars has auto makers taking varied paths, with growing Canada-U.S. collaboration across supply chains.

While most make the battery pack, a large metal enclosure often lining the bottom of the car, they also need the cells that are bundled together to form the core electricity storage.

Tesla several years ago opened its Gigafactory in Nevada to make batteries with Panasonic, which in the shared space would produce cells for the packs. The electric-car maker wanted to secure production specifically for its own models and lower manufacturing and logistics costs.

Now it is looking to in-source more of that production.

While Tesla will continue to buy cells from Panasonic and other suppliers, it is also working on its own cell technology and production capabilities, aiming for cheaper, more powerful batteries to ensure it can keep up with demand for its cars, said Chief Executive Elon Musk last month.

Following Tesla’s lead, General Motors Co. and South Korea’s LG Chem are putting $2.3 billion into a nearly 3-million-square-foot factory in Lordstown, Ohio, highlighting opportunities for Canada to capitalize on the U.S. EV pivot as supply chains evolve, which GM says will eventually produce enough battery cells to outfit hundreds of thousands of cars each year.

In Europe, Volkswagen AG is taking a similar path, investing about $1 billion in Swedish battery startup Northvolt AB, including some funding to build a cell-manufacturing plant in Salzgitter, Germany, as part of a joint venture, and in North America, EV assembly deals in Canada are putting it in the race as well.

Others like Ford Motor Co. and Daimler AG are steering clear of manufacturing their own cells, with executives saying they prefer contracting with specialized battery makers.

Supply-chain disruptions, including lithium shortages, have already challenged some new model launches and put projects at risk, auto makers say.

For instance, Ford and VW have agreements in place with SK Innovation to supply battery cells for future electric-vehicle models. The South Korean company is building a factory in Georgia to help meet this demand, but a fight over trade secrets has put the plant’s future in jeopardy and could disrupt new model launches, both auto makers have said in legal filings.

GM executives say the risk of relying on suppliers has pushed them to produce their own battery cells, albeit with LG Chem.

“We’ve got to be able to control our own destiny,” said Ken Morris, GM’s vice president of electric vehicles.

Bringing the manufacturing in house will give the company more control over the raw materials it purchases and the battery-cell chemistry, Mr. Morris said.

But establishing production, even in a joint venture, is a costly proposition, and it won’t necessarily ensure a timely supply of cells. There are also risks with making big investments on one battery technology because a breakthrough could make it obsolete.

Ford cites those factors in deciding against a similar investment for now.

The company sees the industry’s conventional model of contracting with independent suppliers to build parts as better suited to its battery-cell needs, Ford executive Hau Thai-Tang told analysts in August.

“We have the competitive tension with dealing with multiple suppliers, which allows us to drive the cost down,” Mr. Thai-Tang said, adding that the company expects to pay prices for cells in line with GM and Tesla.

Meanwhile, Ford can leave the capital-intensive task of conducting the research and setting up manufacturing facilities to the battery companies, Mr. Thai-Tang said.

Germany’s Daimler has tried both strategies.

The car company made its own lithium-ion cells through a subsidiary until 2015. But the capital required to scale up was better spent elsewhere, said Ola Källenius, Daimler’s chief executive officer.

The auto maker instead signed long-term supply agreements with Asian companies like Chinese battery-maker CATL and Farasis Energy (Ganzhou) Co., which Daimler invested in last year.

The company has said it is spending roughly $23.6 billion on purchase agreements but keeping its battery research in-house.

“Let’s rather put that capital into what we do best, cars,” Mr. Källenius said.

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nanoFlowcell Bi-ION Flow Battery delivers renewable-energy storage for EVs and grids, using seawater-derived electrolyte, membrane stacks, fast refueling, low-cost materials, scalable tanks, and four-motor performance with long range and lightweight energy density.

Key Points

A flow cell using Bi-ION to power EVs and grids with fast refueling and scalable, low-cost storage.

✅ Seawater-derived Bi-ION electrolyte; safe, nonflammable, low cost

✅ Fast refueling via dual tanks; membrane stack generates power

✅ EV range up to 1200 miles; scalable for grid-scale storage

nanoFlowcell is a European company headquartered in London that focuses on flow battery technology. Flow batteries are an intriguing concept. Unlike lithium batteries or fuel cells, they store electricity in two liquid chambers separated by a membrane. They hold enormous potential for low cost, environmentally friendly energy storage because the basic materials are cheap and abundant. To add capacity, simply make the tanks larger.

While that makes flow batteries ideal for energy storage — whether in the basement of a building or as part of a grid scale installation that utilities weigh against options like hydrogen for power companies today in practice — their size and weight make them a challenge for use in vehicles. That hasn’t stopped nanoFlowcell from designing a number of concept and prototype vehicles over the past 10 years and introducing them to the public at the Geneva auto show. Its latest concept is a tasty little crumpet known as the Quantino 25.

The Flow Battery & Bi-ION Fluid
The thing that makes the nanoFlowcell ecosystem work is an electrically charged fluid called Bi- ION derived from seawater or reclaimed waste water. It works sort of like hydrogen in a fuel cell, a frequent rival in debates over the future of vehicles today for many buyers. Pump hydrogen in, run it through a fuel cell, and get electricity out. With the Quantino 25, which the company calls a “2+2 sports car,” you pump two liquids to the membrane interface to make electricity.

There are two 33-gallon tanks mounted low in the chassis much the way a lithium-ion battery pack fits into a normal electric car. Fill up with Bi-ION, and you have a car that will dash to 100 km/h in 2.5 seconds, thanks to its 4 electric motors with 80 horsepower each. And get this. According to Autoblog, the company says with full tanks, the Quantino 25 has a range of 1200 miles! Goodbye range anxiety, hello happy motoring.

We should point out that water weighs about 8 pounds per gallon, so the “fuel” to travel 1200 miles would weigh roughly 528 pounds. A conventional lithium-ion battery pack with its attendant cooling apparatus that could travel that far would weigh at least 3 times as much, even as EV battery recycling advances aim for a circular economy today. Granted, the Quantino 25 is not a production car and very few people have ever driven one, but that kind of range vs weight ratio has got to get your whiskers twitching a little in anticipation.

Actually, the folks at Autocar did drive an early prototype in 2016 at the TCS test track near Zurich, Switzerland, and determined that it was a real driveable car. My colleague Jennifer Sensiba reported in April of 2019 that the company’s Quantino test vehicle passed the 350,000 km mark (220,000 miles) with no signs of damage to the membrane or the pumps, and didn’t seem to have suffered any wear at all. The vehicle’s engineers pointed out that it had driven for 10,000 hours at this point. The company says it wants to offer its flow battery technology to EV manufacturers and give the system a 50,000-hour guarantee. That translates to well over 1 million miles of driving.

The problem, of course, is that there is no Bi-ION refueling infrastructure just yet, but that doesn’t mean someday there couldn’t be. Tesla had no Supercharger network when it first started either and things turned out reasonably well for Musk and company.

nanoFlowcell USA Announced
nanoFlowcell announced this week that it has established a new division based in New York to bring its flow battery technology to America. The mission of the new division is to adapt the nanoFlowcell process to US-specific applications and develop nanoFlowcell applications in America. Priority one is beginning series production of flow battery vehicles as well as the constructing a large scale bi-ION production facility that will provide transportable renewable energy and could complement vehicle-to-grid power models for communities for nanoFlowcell applications.

The Bi-ION electrolyte is a high density energy carrier that makes renewable energies storable and transportable in large quantities. The company says it will produce the energy carrier bi-ION from 100 percent renewable energy. Flow cell energy technology is an important solution to substantially reduce global greenhouse gas emissions as laid out in the Paris Agreement, the company says. Its many benefits include being a safe and clean energy source for many energy intensive processes and transportation services.

“Our nanoFlowcell flow cell and bi-ION energy carrier are key technologies for a successful energy transition,” says Nunzio La Vecchia, CEO of nanoFlowcell Holdings. “We need to make energy from renewable energy safe, storable and transportable to drive environmentally sustainable economic growth. This requires a well thought out strategy and the development of the appropriate infrastructure. With the establishment of nanoFlowcell USA, we are reaching an important milestone in this regard for our future corporate development.”

Focus On Renewable Energy
The production costs of Bi-ION are directly linked to the cost of electricity from renewable sources. With the accelerated expansion of renewable energy under the Inflation Reduction Act along with EV grid flexibility efforts across markets, nanoFlowcell expects the cost of electricity from solar power to be relatively low in the future which will further strengthen the competitiveness of energy sources such as Bi-ION.

“With the Inflation Reduction Act, the U.S. has made the largest investment in clean energy in U.S. history, and the potential implications for renewable energy are far-reaching.” But La Vecchia points out, “We will not seek government investments for nanoFlowcell USA to expand our manufacturing facilities and infrastructure in the United States. Where appropriate, we will enter into strategic partnerships to build and expand manufacturing and infrastructure, and to integrate nanoFlowcell technologies into all sectors of the economy.”

“More importantly, with nanoFlowcell USA, we want to help accelerate the decarbonization of the global economy and create economic, social and ecological prosperity. After all, estimates suggest that the clean energy sector will create 500,000 additional jobs. We want to do our part to make this happen.”

‍The Takeaway
nanoFlowcell is about more than electric cars. It wants to get involved in grid-scale energy storage, and moves like Mercedes-Benz energy storage venture signal momentum in the sector today. But to those of us soaking in the hot tub warmed by excess heat from a nearby data center here at CleanTechnica global headquarters, it seems that its contribution to emissions-free transportation could be enormous. Maybe some of those companies still chasing the hydrogen fuel cell dream, as a recent hydrogen fuel cell report notes Europe trailing Asia today, might find the company’s flow battery technology cheaper and more durable without all the headaches that go with making, storing, and transporting hydrogen.

A Bi-ION refueling station would probably cost less than a tenth as much as a hydrogen filling station. A link-up with a major manufacturer would make it easier to build out the infrastructure needed to make this dream a reality. Hey, people laughed at Tesla in 2010. If nothing else, this is a company we will be keeping our eye on.

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EV Carpocalypse signals potential mismatch between electric vehicle production and demand, as charging infrastructure, utility coordination, and plug-in hybrid strategies lag forecasts, while state mandates and market-share plays drive cautious, data-informed scaling.

Key Points

EV Carpocalypse describes overbuilt EV supply versus demand amid charging rollout, mandates, and risk-managed scaling.

✅ Forecasts vs actual EV demand may diverge in near term

✅ Charging infrastructure and utilities lag vehicle output

✅ Mandates and PHEVs cushion adoption while data guides scaling

According to Forbes contributor David Kiley, and Wards Automotive columnist John McElroy, there may be an impending “carpocalypse” of electric vehicles on the way. Sounds very damning and it’s certainly not the upbeat tone I’ve taken on nearly every piece of EV demand content I’ve authored but the author, Kiley does bring up some interesting points worth considering. EV Adoption is happening, and it’s certainly doing so at ever faster rates as the market nears an EV inflection point today. The infrastructure (charging stations, utility cooperation) is being built out more slowly than vehicle manufacturers are producing cars but, as the GM president on EV hurdles has noted, the issue seems to be just that, maybe even the short and medium term plans for EV manufacturing are too aggressive.

#google#

With new EV and plug-in hybrid vehicle sales representing a mere .6% of new car cales in the US, a sign that EV sales remain behind gas cars even as new models proliferate, car makers are are going to be spending more than $100 billion to come out with more than a hundred models of battery electric vheicles which also includes PHEVs and the fear is these vehicles aren’t going to sell in the numbers that automakers and industry analysts may have expected. But forecasts are just that, forecasts, even as U.S. EV sales surge into 2024 suggest momentum. So there’s a valid argument to be made that they’ll either overshoot the true mark or come in way below the actual amount. With nine U.S. states mandating that 15% of new cars sold be EVs by 2025, you could say that at least automakers have supporters in state government helping to push the new technology into the hands of more drivers.

Still, it’s anyone’s guess as to what true adoption will be, and a brief Q1 2024 market share dip underscores lingering volatility. The use of big data and just in time manufacturing will ensure that manufacturers will miss the mark on EVs by less than they have in the past, and will able to cope with breaking even on these vehicles for the sake of gobbling up precious early stage market share. After all, many vendors have up to this point been very willing to break even or make a loss on their lease-only EVs or on EV or hybrid financing in order to gain that share and build out their brand awareness and technical prowess. With some stops and starts, demand will meet supply or supply may need to meet demand but either way, the EV adoption wave is coming to a driveway near you. 

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Clean Coal Technologies Pristine Funding secures investment from a New York asset manager via Black Diamond, advancing commercialization, Tulsa testing, Wyoming relocation, PRB coal enhancement, and cleaner energy innovation to support global coal exports.

Key Points

Capital from a New York asset manager backs Pristine commercialization, testing, and Wyoming relocation to boost PRB coal.

✅ Investment via Black Diamond funds Tulsa test operations.

✅ Permanent relocation planned near a Wyoming mine site.

✅ First Pristine M module to enhance PRB coal quality.

Clean Coal Technologies, Inc., an emerging cleaner-energy company utilizing patented and proven technology to convert untreated coal into a cleaner burning and more efficient fuel, announced today that the company has secured funding for their Pristine technology through commercialization, a move reminiscent of Bruce C project funding activity, from a major New York-based Asset Management company. This investment will be made through Black Diamond with all funds earmarked for test procedures at the plant near Tulsa, OK, at a time when rare new coal plants are appearing, and the plant's move to a permanent location in Wyoming. The first tranche is being paid immediately.

"Securing this investment will confidently carry us through to the construction of our first commercial module enabling management to focus on the additional tests that have been requested from multiple parties, even as US coal demand faces headwinds across the market," stated CEO of Clean Coal Technologies, Inc., Robin Eves. "At this time we have begun scheduling plant visits with both US government agency and coal industry officials along with key international energy consortiums that are monitoring transitions such as Alberta's coal phaseout policies."

"We're now able to finalize our negotiations in Wyoming where the permitting process has begun and where we will permanently relocate the test facility later this year following completion of the aforementioned tests," added CCTI COO/CFO, Aiden Neary. "This event also paves the way forward to commence the process of constructing the first commercial Pristine M facility. That plant is planned to be in Wyoming near an operating mine where our process can be used to enhance the quality of PRB coal to make it more competitive globally, even as regions like western Europe see coal-to-renewables conversions at legacy plants, and help restore the US coal export market."

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Maxeon IBC Solar Factory USA will scale clean energy with high-efficiency interdigitated back contact panels, DOE-backed manufacturing in Albuquerque, utility-scale supply, domestic production, 3 GW capacity, reduced imports, carbon-free electricity leadership.

Key Points

DOE-backed Albuquerque plant making high-efficiency IBC panels, 3 GW yearly, for utility-scale, domestic solar supply.

✅ 3 GW annual capacity; up to 8 million panels produced

✅ IBC cell efficiency up to 24.7% for utility-scale projects

✅ Reduces U.S. reliance on imported panels via domestic manufacturing

Solar energy stands as a formidable source of carbon-free electricity, with the No. 3 renewable source in the U.S. offering a clean alternative to traditional power generation methods reliant on polluting fuels. Advancements in solar technology continue to emerge, with a U.S.-based company poised to spearhead progress from a cutting-edge factory in New Mexico.

Maxeon, initially hailing from Silicon Valley in the 1980s, recently ventured into independence after separating from its parent company, SunPower, in 2020. Over the past few years, Maxeon has been manufacturing solar panels in Mexico, Malaysia, and the Philippines, as record U.S. panel shipments underscored rising demand.

Now, with backing from the U.S. Department of Energy's Loans Programs Office, Maxeon is preparing to commence construction on a new facility in Albuquerque in 2024, amid unprecedented growth in solar and storage nationwide. This state-of-the-art factory aims to produce up to 8 million panels annually, featuring the company's interdigitated back contact (IBC) technology, which has the capacity to generate three gigawatts of power each year. Notably, the entire U.S. solar industry completed five gigawatts of panels in 2022, making Maxeon's endeavor particularly ambitious and aligned with Biden's proposed tenfold increase in solar power goals.

Maxeon's presence in the United States holds the potential to reduce the country's reliance on imported panels, particularly from China. The primary focus will be on providing this advanced technology for utility departments, where pairing with increasingly affordable batteries can enhance grid reliability while shifting away from residential and commercial rooftops.

Maxeon has achieved a remarkable milestone in solar efficiency, with its latest IBC technology boasting an efficiency rating of 24.7%, as reported by PV Magazine.

This strategic move to the United States could be a game-changer, not only for Maxeon's success but also for clean power generation in a nation that has traditionally depended on external sources for its supply of solar panels, as energy-hungry Europe turns to U.S. solar equipment makers for solutions. Matt Dawson, Maxeon's Chief Technology Officer, emphasized the importance of achieving the lowest levelized cost of electricity with the lowest overall capital, a feat that China has accomplished in recent years due to the strength of its supply chain. As energy independence becomes a global concern, solar manufacturing is poised to expand beyond China, with Southeast Asia already showing signs of growth, and now the United States and possibly Europe, including Germany's solar boost during the energy crisis, following suit.

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U.S. Offshore Wind Power Strategy leverages UK offshore wind lessons, contract auctions, and supply chains to scale renewable energy, build wind farms, cut emissions, create jobs, and modernize the grid to meet 2030 climate goals.

Key Points

U.S. plan to scale offshore wind via UK-style contracts, turbines, and supply chains to meet 2030 clean energy goals

✅ Contract-for-difference price guarantees de-risk projects

✅ Scale turbines and ports to cut LCOE and boost capacity

✅ Build coastal grids, transmission, and workforce by 2030

As President Joe Biden’s administration puts its muscle behind wind power with plans to develop large-scale wind farms along the entire United States coastline, the administration can look at how the windiest nation in Europe is transforming its energy grid for an example of how to proceed.

In the search for renewable sources of energy, the United Kingdom has embraced wind power. In 2020, the country generated as much as 24 percent of its electricity from wind power across the grid — enough to supply 18.5 million homes, according to government statistics. 

With usually reliable winds, the U.K. currently has the highest number of offshore turbines installed in the world, with China at a close second.

Experts and industry leaders say it offers valuable lessons on creating a viable market for wind power at the ambitious scale the Biden administration hopes to meet in order to confront climate change and help transition the U.S. economy to renewable energy.

“The U.S. is going to benefit hugely from the early investment that European governments have put into offshore wind,” said Oliver Metcalfe, a wind power analyst at BloombergNEF in London, an independent research group.

Big American plans
On Oct. 13, the White House announced ambitious offshore wind plans to lease federal waters off of the East and West Coasts and Gulf of Mexico to develop commercial wind farms.

The move is part of Biden’s goal to have 30,000 megawatts of offshore wind power produced in the United States by 2030, with projects such as New York's record-setting approval highlighting the momentum. The White House says that would generate enough electricity to power more than 10 million homes and in the process create 77,000 jobs. 

But there is a chasm between where the U.S. is now and where it wants to be within the next decade when it comes to offshore wind power.

“We’re the first generation to understand the science and implications of climate change and we’re the last generation to be able to do something about it.”

The U.S. is not new to wind power; onshore wind in states such as Texas, Oklahoma and Iowa supplied 8.2 percent of the country’s total electricity generation in 2020, according to the U.S. Department of Energy. 

But despite its long coastlines, offshore wind has been a largely untapped resource in the U.S. With a population of about 332 million people, the U.S. currently has just two operational offshore wind farms — off Rhode Island and Virginia — with the capacity to produce 42 megawatts of electricity between them, far from the 1 gigawatt on-grid milestone many are watching. 

In contrast, the U.K., with a population of 67 million people, has 2,297 offshore wind turbines with the capacity to produce 10,415 megawatts of electricity.

Power station or a park?
Just outside of central Glasgow, the host city for the U.N. climate change conference known as COP26, the fruits of years of effort to move away from fossil fuels can be seen and heard

International financiers, including the World Bank are helping developing countries scale wind projects to meet climate goals.

Whitelee Windfarm, the U.K.’s largest onshore wind farm, spreads across 30 square miles on the Eaglesham Moor and includes more than 80 miles of trails for walking, cycling and horseback riding.

With its 539 megawatt capacity, it generates enough electricity for 350,000 homes — more than half the population of Glasgow. 

On a recent gusty fall day, Ian and Fiona Gardner, both 71, were walking their dogs among the wind farm’s 360-foot-tall turbines  

“This is a major contribution to Scotland, to become independent from oil by 2035,” Ian Gardner, an accountant, said. 

Thanks to the rapid technological advances in turbine technology, this wind farm that was completed in 2009, is now practically old school. The latest crop of onshore turbines typically generate double the current capacity of Whitelee’s turbines.

“It took us 20 years to build 2 gigawatts of power. And we’re going to double that in five  years,” said McQuade, an economist. “We can do that because machines are big, efficient, cheap and the supply chain is there.” 

The biggest operational offshore wind farm in the world right now, Hornsea Project One, is about 75 miles off England’s Yorkshire coast in the North Sea.

Owned and operated by Orsted, a former Danish oil and gas giant, in partnership with Global Infrastructure Partners, its 174 turbines have the capacity to generate 1.2 gigawatts — enough to power over 1 million homes and roughly equivalent to a nuclear power plant. 

Benj Sykes, Vice President of U.K. Offshore Wind at Orsted, called Hornsea One a “game changer” in a recent phone interview, citing it as an example of how the industry has scaled up its output to compete with traditional power plants.

But massive projects like Hornsea One took decades to get up and running, as well as government help. According to Malte Jansen, a research associate at the Centre of Environmental Policy at Imperial College London, the British government helped facilitate a “paradigm shift” in renewable energy in 2013.

The electricity market reform policy set up a framework to incentivize investment in offshore wind farms by creating an auction system that guarantees electricity prices to developers in 15-year contracts, alongside new contract awards that add 10 GW to the U.K. grid. 

This means there is no upside in terms of market price fluctuation, but there is no downside either. The policy essentially “de-risked the investment,” Jansen said.

The state contracts allowed the industry to innovate and learn how to develop even larger and more efficient turbines with blades that stretch as long as 267 feet, about three-quarters the size of a U.S. football field. 

While this approach helped companies and investors, it will also have an unintended beneficiary — the U.S., Metcalfe from BloombergNEF said. 

Developers are “taking the lessons they’ve learned building projects in Europe, the cost reductions that they’ve achieved building projects in Europe and are now bringing those to the U.S. market,” he said.

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