U.S. to work with allies to secure electric vehicle metals

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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US electric vehicle momentum is slowing as tax credits expire, tariffs increase costs, and interest rates rise, while Europe and China accelerate EV adoption through stronger incentives, enhanced charging infrastructure, and growth in battery manufacturing.

Why has US Electric Vehicle Momentum Slowed as Globe Surges?

US electric vehicle momentum has slowed due to expiring subsidies, rising costs, and global competition from faster-moving markets.

✅ End of federal tax credits weakened buyer demand

✅ Tariffs and high interest rates raised EV prices

✅ Europe and China expanded incentives and infrastructure

You could be forgiven for thinking that electric cars might finally be gaining momentum in the United States. Last year, battery-powered vehicle sales topped 1.2 million—more than five times the number sold just four years earlier, amid an early-2024 EV surge in deliveries. Hybrid sales tripled over the same period, and in August, battery cars accounted for 10 percent of all new vehicle sales, a record high according to S&P Global Mobility.

Major automakers, including General Motors, Ford, and Tesla, reported record electric-vehicle deliveries this quarter, a rare bright spot in an industry still contending with high interest rates, inflation, and tariffs, and a sign the age of electric cars is arriving.

Yet analysts warn the apparent boom may be short-lived, noting a market share dip in early 2024 that could foreshadow slower growth. Much of the recent surge was driven by buyers rushing to take advantage of a federal subsidy worth up to $7,500 per vehicle—a credit that expired at the end of September. Without it, automakers expect demand to dip sharply.

"It's going to be a vibrant industry, but it's going to be smaller, way smaller than we thought," Ford CEO Jim Farley said Tuesday. General Motors’ CFO Paul Jacobson echoed that concern: "I expect that EV demand is going to drop off pretty precipitously," he told a conference last month.

Even with those gains, the US—still the world’s second-largest car market—remains a laggard compared with global peers, where global EV adoption has accelerated rapidly. Electric and hybrid vehicles accounted for nearly 30 percent of new sales in the UK last year and approximately one in five across Europe. In China, electric models accounted for almost half of all car sales in 2023 and are expected to become the majority this year, according to the International Energy Agency.

Analysts say policy differences largely explain the gap. Other regions have offered stronger incentives, stricter emissions rules, and more aggressive trade-in programs. President Joe Biden tried to close the gap, tightening emissions standards, offering loans for EV investments, and spending billions on charging networks while expanding the $7,500 credit. His goal was to have half of all US vehicle sales be electric by 2030.

Supporters argue that such measures are crucial to keeping American carmakers competitive with Chinese and European manufacturers. But former President Donald Trump, who recently dismissed climate change as a "con job," has vowed to roll back many of those initiatives, echoing arguments that the EV revolution is overstated by proponents. "We're saying ... you're not going to be forced to make all of those cars," Trump said this summer, while signing a bill to strike down California’s plan to phase out gasoline-only car sales by 2035. "You can make them, but it'll be by the market, judged by the market."

Although EVs have become cheaper, they still cost more than comparable gasoline models, and sales remain behind gas cars in most segments. The average US electric car sold for approximately $57,000 in August, which is roughly 16 percent higher than the overall average, according to Kelley Blue Book.

Chinese EV giants such as BYD have been blocked from the US market by tariffs supported by both Biden and Trump, further limiting price competition. Automakers now face the twin challenges of rising tariffs and disappearing subsidies.

"It would have been difficult enough if all you had to deal with were new tariffs, but with new tariffs and the incentive going away, there are two impacts," said Stephanie Brinley of S&P Global Mobility.

Researchers warn that the policy shift could further reduce EV investment. "It's a big hit to the EV industry—there's no tiptoeing around it," said Katherine Yusko of the American Security Project. "The subsidies were initially a way to level the playing field, and now that they're gone, the US has a lot of ground to make up."

Still, Brinley urged caution before declaring the race lost, even as some argue EVs have hit an inflection point in adoption. "Is [electric] really the right thing?" she asked. "Saying that we're behind assumes that this is the only and best solution, and I think it's a little early to say that."

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Electric Vehicle Charging Costs and Times explain kWh usage, electricity rates, Level 2 vs DC fast charging, per-mile expense, and tax credits, with examples by region and battery size to estimate home and public charging.

Key Points

They measure EV charging price and duration based on kWh rates, charger level, efficiency, and location.

✅ Costs vary by kWh price, region, and charger type.

✅ Efficiency (mi/kWh) sets per-mile cost and range.

✅ Tax credits and utility rates impact total ownership.

More and more car manufacturing companies dip their toes in the world of electric vehicles every year, making it a good time to buy an EV for many shoppers, and the U.S. government is also offering incentives to turn the tides on car purchasing. Electric vehicles bought between 2010 and 2022 may be eligible for a tax credit of up to $7,500. 

And according to the Consumer Reports analysis on long-term ownership, the cost of charging an electric vehicle is almost always cheaper than fueling a gas-powered car – sometimes by hundreds of dollars.

But that depends on the type of car and where in the country you live, in a market many expect to be mainstream within a decade across the U.S. Here's everything you need to know.

How much does it cost to charge an electric car?
An electric vehicle’s fuel efficiency can be measured in kilowatt-hours per 100 miles, and common charging-efficiency myths have been fact-checked to correct math errors.

For example, if electricity costs 10.7 cents per kilowatt-hour, charging a 200-mile range 54-kWh battery would cost about $6. Charging a vehicle that consumes 27 kWh to travel 100 miles would cost three cents a mile. 

The national average cost of electricity is 10 cents per kWh and 11.7 cents per kWh for residential use. Idaho National Laboratory’s Advanced Vehicle Testing compares the energy cost per mile for electric-powered and gasoline-fueled vehicles.

For example, at 10 cents per kWh, an electric vehicle with an efficiency of 3 miles per kWh would cost about 3.3 cents per mile. The gasoline equivalent cost for this electricity cost would be just under $2.60 per gallon.

Prices vary by location as well. For example, Consumer Report found that West Coast electric vehicles tend to be less expensive to operate than gas-powered or hybrid cars, and are often better for the planet depending on local energy mix, but gas prices are often lower than electricity in New England.

Public charging networks in California cost about 30 cents per kWh for Level 2 and 40 cents per kWh for DCFC. Here’s an example of the cost breakdown using a Nissan LEAF with a 150-mile range and 40-kWh battery:

Level 2, empty to full charge: $12
DCFC, empty to full charge: $16

Many cars also offer complimentary charging for the first few years of ownership or provide credits to use for free charging. You can check the full estimated cost using the Department of Energy’s Vehicle Cost Calculator as the grid prepares for an American EV boom in the years ahead.

How long does it take to charge an electric car?
This depends on the type of charger you're using. Charging with a Level 1 charger takes much longer to reach full battery than a level 2 charger or a DCFC, or Direct Current Fast Charger. Here's how much time you can expect to spend charging your electric vehicle:

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North Central Energy Facilities deliver 1,484 MW of renewable power in Oklahoma, uniting Invenergy, GE Renewable Energy, and AEP with the Traverse, Maverick, and Sundance wind farms, 531 turbines, grid-scale clean energy, and regional decarbonization.

Key Points

A 1,484 MW trio of Oklahoma wind farms by Invenergy with GE turbines, owned by AEP to supply regional customers.

✅ 1,484 MW capacity from 531 GE 2 MW platform turbines

✅ Largest single-phase wind farm: 998 MW Traverse

✅ Owned by AEP subsidiaries SWEPCO and PSO

Invenergy, the largest privately held global developer, owner and operator of sustainable energy solutions and GE Renewable Energy, today announced commercial operations for the 998-megawatt Traverse Wind Energy Center, the largest wind farm constructed in a single phase in North America, reflecting broader growth such as Enel's 450 MW project announced recently.

Located in north central Oklahoma, Traverse joins the operational 199-megawatt Sundance Wind Energy Center and the 287-megawatt Maverick Wind Energy Center, as the last of three projects developed by Invenergy for American Electric Power (AEP) to reach commercial operation, amid investor activity like WEC Energy's Illinois stake in wind assets this year. These projects make up the North Central Energy Facilities and have 531 GE turbines with a combined capacity of 1,484 megawatts, making them collectively among the largest wind energy facilities globally, even as new capacity comes online such as TransAlta's 119 MW addition in the US.

"This is a moment that Invenergy and our valued partners at AEP, GE Renewable Energy, and the gracious members of our home communities in Oklahoma have been looking forward to," said Jim Shield, Senior Executive Vice President and Development Business Leader at Invenergy, reflecting broader momentum as projects like Building Energy project begin operations nationwide. "With the completion of Traverse and with it the North Central Energy Facilities, we're proud to further our commitment to responsible, clean energy development and to advance our mission to build a sustainable world."

The North Central Energy Facilities represent a $2 billion capital investment in north central Oklahoma, mirroring Iowa wind investments that spur growth, directly investing in the local economy through new tax revenues and lease payments to participating landowners and will generate enough electricity to power 440,000 American homes.

"GE was honored to work with Invenergy on this milestone wind project, continuing our long-standing partnership," said Steve Swift, Global Commercial Leader for GE's Onshore Wind business, a view reinforced by projects like North Carolina's first wind farm coming online. "Wind power is a key element of driving decarbonization, and a dependable and affordable energy option here in the US and around the world. GE's 2 MW platform turbines are ideally suited to bring reliable and sustainable renewable energy to the region for many years to come."

AEP's subsidiaries Southwestern Electric Power Company (SWEPCO) and Public Service Company of Oklahoma (PSO) assumed ownership of the three wind farms upon start of commercial operations, alongside emerging interstate delivery efforts like Wyoming-to-California wind plans, to serve their customers in Arkansas, Louisiana and Oklahoma.

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2020 U.S. Renewable Electricity Generation set a record as wind, solar, hydro, biomass, and geothermal produced 834 billion kWh, surpassing coal and nuclear, second only to natural gas in nationwide power output.

Key Points

The record year when renewables made 834 billion kWh, topping coal and nuclear in U.S. electricity.

✅ Renewables supplied 21% of U.S. electricity in 2020

✅ Coal output fell 20% y/y; nuclear slipped 2% on retirements

✅ EIA forecasts renewables rise in 2021-2022; coal rebounds

In 2020, renewable energy sources (including wind, hydroelectric, solar, biomass, and geothermal energy) generated a record 834 billion kilowatthours (kWh) of electricity, or about 21% of all the electricity generated in the United States. Only natural gas (1,617 billion kWh) produced more electricity than renewables in the United States in 2020. Renewables surpassed both nuclear (790 billion kWh) and coal (774 billion kWh) for the first time on record. This outcome in 2020 was due mostly to significantly less coal use in U.S. electricity generation and steadily increased use of wind and solar generation over time, amid declining consumption trends nationwide.

In 2020, U.S. electricity generation from coal in all sectors declined 20% from 2019, while renewables, including small-scale solar, increased 9%. Wind, currently the most prevalent source of renewable electricity in the United States, grew 14% in 2020 from 2019, and the EIA expects solar and wind to be larger sources in summer 2022, reflecting continued growth. Utility-scale solar generation (from projects greater than 1 megawatt) increased 26%, and small-scale solar, such as grid-connected rooftop solar panels, increased 19%, while early 2021 January power generation jumped year over year.

Coal-fired electricity generation in the United States peaked at 2,016 billion kWh in 2007 and much of that capacity has been replaced by or converted to natural gas-fired generation since then. Coal was the largest source of electricity in the United States until 2016, and 2020 was the first year that more electricity was generated by renewables and by nuclear power than by coal (according to our data series that dates back to 1949). Nuclear electric power declined 2% from 2019 to 2020 because several nuclear power plants retired and other nuclear plants experienced slightly more maintenance-related outages.

We expect coal-fired generation to increase in the United States during 2021 as natural gas prices continue to rise and as coal becomes more economically competitive. Based on forecasts in our Short-Term Energy Outlook (STEO), we expect coal-fired electricity generation in all sectors in 2021 to increase 18% from 2020 levels before falling 2% in 2022. We expect U.S. renewable generation across all sectors to increase 7% in 2021 and 10% in 2022, and in 2021, non-fossil fuel sources accounted for about 40% of U.S. electricity. As a result, we forecast coal will be the second-most prevalent electricity source in 2021, and renewables will be the second-most prevalent source in 2022. We expect nuclear electric power to decline 2% in 2021 and 3% in 2022 as operators retire several generators.

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Sicily Green Hydrogen accelerates decarbonization via renewable energy, wind farm electrolysis, hydrogen storage, and distribution from Enel Green Power and Sapio at the NextHy industrial lab in Carlentini and Sortino Sicily hub.

Key Points

Sicily Green Hydrogen is an Enel-Sapio plan to produce hydrogen via wind electrolysis for industrial decarbonization.

✅ 4 MW electrolyzer powered by Carlentini wind farm

✅ Estimated 200+ tons annual green H2 production capacity

✅ Market distribution managed by Sapio across Sicily

This green hydrogen will be produced at the Sicilian industrial plant, an innovative hub that puts technology at the service of the energy transition, echoing hydrogen innovation funds that support similar goals worldwide

Activating a supply of green hydrogen produced using renewable energy from the Carlentini wind farm in eastern Sicily is the focus of the agreement signed by Enel Green Power and Sapio. The agreement provides for the sale to Sapio of the green hydrogen that will be produced, stored in clean energy storage facilities and made available from 2023 at the Carlentini and Sortino production sites, home to Enel Green Powers futuristic NextHy innitiative. Sapio will be responsible for developing the market and handling the distribution of renewable hydrogen to the end customer.

In contexts where electrification is not easily achievable, green hydrogen is the key solution for decarbonization as it is emission-free and offers a potential future for power companies alongside promising development prospects, commented Salvatore Bernabei, CEO of Enel Green Power. For this reason we are excited about the agreement with Sapio. It is an agreement that looks to the future by combining technological innovation and sustainable production.

Sapio is strongly committed to contributing to the EUs achievement of the UN SDGs, commented Alberto Dossi, President of the Sapio Group, and with this project we are taking a firm step towards sustainable development in our country. The agreement with EGP also gives us the opportunity to integrate green hydrogen into our business model, as jurisdictions propose hydrogen-friendly electricity rates to grow the hydrogen economy, which is based on our strong technological expertise in hydrogen and its distribution over 100 years in business. In this way we will also be able to give further support to the industrial activities we are already carrying out in Sicily.

The estimated 200+ tons of production capacity of the Sicilian hub is the subject of the annual supply foreseen in the agreement. Once fully operational, the green hydrogen will be produced mainly by a 4 MW electrolyzer, which is powered exclusively by the renewable energy of the existing wind farm, and to a lesser extent by the state-of-the-art electrolysis systems tested in the platform. Launched by Enel Green Power in September 2021, NextHys Hydrogen Industrial Lab is a unique example of an industrial laboratory in which production activity is constantly accompanied by technological research. In addition to the sectors reserved for full-scale production, there are also areas dedicated to testing new electrolyzers, components such as valves and compressors, and innovative storage solutions based on liquid and solid means of storage: in line with Enels open-ended approach, this activity will be open to the collaboration of more than 25 entities including partners, stakeholders and innovative startups. The entire complex is currently undergoing an environmental impact assessment at the Sicily Regions Department of Land and Environment.

It is an ambitious project with a sustainable energy source at its heart that will be developed at every link in the chain: thanks to the agreement with Sapio, in fact, at NextHy green hydrogen will now not only be produced, stored and moved on an industrial scale, but also purchased and used by companies that have understood that green hydrogen is the solution for decarbonizing their production processes. In this context, this experimental approach that is open to external contributions will allow the Enel Green Power laboratory team to test the project on an industrial scale, so as to create the best conditions for a commercial environment that can make the most of all present and future technologies for the generation, storage and transport of green hydrogen, including green hydrogen microgrids that demonstrate scalable integration. It is an initiative consistent with Enels Open Innovability spirit: meeting the challenges of the energy transition by focusing on innovation, ideas and their transformation into reality.

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