The purpose of the study summarized in this report was to examine the current state of the leading advanced EV-battery technologies and to assess the prospective costs and commercial availability of these technologies in the year 2003 or soon thereafter.
As in the 1995 BTAP report, the Panel defines “commercial availability” as commercially available for electric vehicle applications, with the performance and reliability of the battery having been demonstrated, the battery having been engineered into a vehicle, and the battery/vehicle combination subjected to validation testing. The word “commercial” implies that the cost of the batteries to EV manufacturers and owners allows the introduction of EVs into economically viable markets.
The main focus of the Panel’s study was the investigation of the battery technologies that in 1995 were leading candidates to achieve major performance gains over lead-acid batteries, appear to have some prospects for meeting EV-battery cost targets, and are now available from low volume production lines or, at least, laboratory pilot facilities. In the Panel’s view, advanced batteries not meeting these selection criteria are highly unlikely to be available for commercial introduction within the next five years. Although the focus of the BTAP 2000 study thus was on advanced batteries, the Panel briefly reviewed the improved lead-acid EV battery technologies used in EVs operating in California today. As discussed in Appendix F of this report, the Panel found that these batteries are indeed improved but remain handicapped by the low specific energy characteristic of all lead-acid batteries, and that lead-acid battery life remains an important concern.
The scope and time horizon of the investigation reported here thus were different from those of the 1998/99 study by one of the Panel members (2) which emphasized candidate EV-battery systems with future (e.g., ten-year or longer-term) prospects for significantly higher specific energy and lower costs. For the nearer-term EV-battery technologies included in the 1998/99 study as benchmarks, the present investigation adds not only a timely update, but also a strong focus on cost and commercial viability in 2003 or soon thereafter.
I.2. STUDY APPROACH
As in the first BTAP study, the present study employed the following means of obtaining and evaluating information:
Use of a questionnaire (see Appendix A.1) to solicit pertinent information from North American, Japanese and European developers and manufacturers of advanced EV-battery technologies with potential for commercial availability in 2003 or soon thereafter. A similar questionnaire (Appendix A.2) was submitted to the six automobile manufacturers (in the U.S. and Japan) currently under obligation to offer EVs for sale beginning in 2003. These manufacturers have active programs to integrate and evaluate advanced batteries in the state-of-the-art electric vehicles developed by them in recent years. The main purpose of these questionnaires was to alert the organizations to the scope of the Panel’s interests and the topics to be discussed during the Panel’s visits.
Visits to all these organizations (see Appendix B), to discuss EV-battery technology development status and issues, current and prospective costs, and in-vehicle evaluation, as well as strategies, plans and issues for the commercial introduction of EVs and EV batteries. The likely future costs of advanced batteries, and possible strategies and schedules for establishing increasing levels of battery and EV production, were central topics in these visits. In addition, Panel members made many contacts with individuals from organizations engaged in various aspects of electric-vehicle technology and operation, including batteries, battery materials and EV development, battery and EV testing, and the promotion and demonstration of EVs.
Critical review of the information collected, identification of knowledge gaps, solicitation of additional information from battery and EV developers/manufacturers, and review of report draft material with information sources, to assure accuracy and avoid inadvertent publication of data and other information given to the Panel in confidence. Panel-internal workshops to review the findings and develop conclusions, and preparation of this report.
Section II below discusses key requirements for EV batteries, with emphasis on costs, and it identifies the advanced-battery systems included in the Panel’s investigation. The Section also includes a discussion of the most important factors contributing to battery costs. Section III details the Panel’s findings from the discussions with battery developers/manufacturers (Sections III.1, III.2, and III.3) and automobile manufacturers (Section III.4). Finally, Section IV presents the Panel’s conclusions from the information collected, discussed with its sources, and subjected to Panel-internal critical discussions.
SECTION II. BATTERIES FOR ELECTRIC VEHICLES
Background. The 1995 BTAP assessment found that several advanced battery types with the potential to meet the mid-term performance and cost targets of the United States Advanced Battery Consortium (USABC) had reached the pre-prototype stage. That Panel also concluded that even the leading candidates among these were unlikely to be commercially available before 2000/2001, and this only in a complete success scenario that required, in particular, firm commitments to battery production plants no later than 1998/99.
In the absence of historic precedent, the 1995 BTAP study had to leave open the question of whether availability of batteries meeting or, at least, coming close to USABC mid-term targets would lead to successful commercialization of electric vehicles (EVs). The study’s battery-cost survey indicated [(1), Table II.4] that the costs of the batteries being developed were likely to be well above USABC mid-term targets, except possibly in large-scale production, adding to the uncertainty about the prospects of EVs.
Over the past five years, battery developers and automobile manufacturers devoted large efforts to the continued advancement of EV-battery technology and the development of a new generation of electric vehicles. Under the MoA between the six leading automobile manufacturers and the California Air Resources Board, a substantial number of these vehicles has been deployed. Nevertheless, since they are produced in limited volume only, the vehicles—including their batteries—are expensive, and vehicle leases had to be subsidized heavily to attract early users.
As the time approaches for critical decision on actions needed to implement the current ZEV provisions, the question again arises whether batteries with the required performance and cost characteristics could be available in time for commercialization of broadly marketable EVs by 2003. The most important requirements that must be met by EV batteries are re-examined below from today’s perspective, and they are used in Section II.2 to identify the candidate EV batteries that were examined more closely by the Panel. The Panel’s findings on EV-battery performance, cost, and prospects for availability in the coming years are summarized in Section III.
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