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At Current Rates, Tesla Could Soon Suck Up Worldwide Supply of Li-Ion Cells

cartechboy writes "Lets just say Elon Musk may need to go battery shopping, like, big-time. Here's some little-understood Tesla math that could turn the global market for cylindrical lithium-ion cells upside down by 2015. It turns out the massive Model S battery takes almost 2,000 times the number of cells a basic laptop does. Assume Tesla just doubles production from its current 21K cars/year to 40K cars/year. (Something it expects to do by 2015). At that point, Tesla would require the *entire* existing global capacity for 18650 commodity cells. That assumes no other growth, no next gen model, nada. What should Elon do? Better get on the horn to Panasonic and Samsung."

41 of 351 comments (clear)

  1. On the plus side... by fuzzyfuzzyfungus · · Score: 5, Insightful

    Our newfound infatuation with extremely flat laptops that have about as many user-servicable parts as 2001's Monolith means that demand for 18650 Li-ion cells in laptops should be plummeting! Problem solved.

    Now we just need to go liberate whoever is living on top of our lithium, and we are good to go.

    1. Re:On the plus side... by dj245 · · Score: 5, Informative

      Our newfound infatuation with extremely flat laptops that have about as many user-servicable parts as 2001's Monolith means that demand for 18650 Li-ion cells in laptops should be plummeting! Problem solved. Now we just need to go liberate whoever is living on top of our lithium, and we are good to go.

      There is a difference between a "battery" or "battery pack" and a "battery cell". One "battery" generally needs to have several "battery cells" inside. The voltage of the battery "cell" is determined by chemistry and can not be changed. To make higher voltages, you need to use more cells or a different chemistry. The simplest example is a 9V (PP3) battery. Alkaline chemistry gives a per-cell output of abour 1.5v, so to get 9v you need 6 cells. Usually this comes in the form of 6 AAAA batteries inside.

      --
      Even those who arrange and design shrubberies are under considerable economic stress at this period in history.
    2. Re:On the plus side... by firex726 · · Score: 3, Interesting

      Yep...
      For your average Li-Ion battery they are in cylindrical cells and output around 3.7v each. Li-Poly are similar but instead of hard cylinders they are laminated sheets one on top of each other, allowing for more variety in shapes and are the most common for phones; downside being they do not put up with as much abuse and can be damaged resulting in an internal short and the eventual boom/fire.

    3. Re:On the plus side... by Joce640k · · Score: 4, Interesting

      The real problem is that nobody's allowed to make big batteries for use in cars because the oil companies bought up all the patents:

      https://en.wikipedia.org/wiki/Patent_encumbrance_of_large_automotive_NiMH_batteries#Chevron_and_Cobasys

      This is the reason they have to use 8000 tiny little flashlight batteries in cars instead of a few dozen big ones.

      --
      No sig today...
    4. Re:On the plus side... by X0563511 · · Score: 4, Insightful

      Perfect example of patents stifling progress instead of encouraging it.

      --
      For large sets, this will be our guide even unto death, for the LORD will work for each type of data it is applied to...
    5. Re:On the plus side... by GodfatherofSoul · · Score: 4, Funny

      Well, it took me 2 seconds to type my question and get a response. That's 3 seconds I have to not be a smug asshole.

      --
      I swear to God...I swear to God! That is NOT how you treat your human!
    6. Re:On the plus side... by Spoke · · Score: 4, Informative

      While large format NiMH batteries are patent encumbered, large format Lithium batteries (the kind used in all EVs today except for Tesla) are not.

      I believe that Toyota is the only manufacturer who currently uses large format NiMH batteries, but only in their hybrids. The referenced wikipedia article suggests Panasonic/Cobasys worked out an agreement as long as Toyota only used those NiMH batteries in hybrids and not in a plug-in vehicle.

      Note that the large format NiMH battery patents are due to expire in 2014.

      Not sure how much of this matters - Lithium batteries are superior to NiMH batteries now in just about every way.

    7. Re:On the plus side... by sl4shd0rk · · Score: 4, Insightful

      Perfect example of patents stifling progress instead of encouraging it.

      It's an even better example of patents serving the precise purpose they were designed to prevent.

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    8. Re:On the plus side... by Areyoukiddingme · · Score: 4, Insightful

      So why exactly are you demonizing oil companies in your post? Sounds like they played a big role in creating these large-format batteries.

      Because they used their battery patent to force Toyota to not only discontinue manufacturing their first pure-electric RAV4, but also pay a large fine for daring to do so. That vehicle was their CUSTOMER, and they killed it with a lawsuit. Toyota would have been paying them royalty money for over a decade, on potentially tens of thousands of vehicles worth of batteries, but they insisted on total shutdown of production instead.

      That's how much oil companies fear the possibility of a successful electric car. They're not "energy companies", all branding efforts to the contrary. They're oil companies. They act exactly the way oil companies have acted for over a century.

    9. Re:On the plus side... by loshwomp · · Score: 3, Informative

      IAAEVE (I am an electric vehicle engineer) and I worked on Li cell, battery, and powertrain technology that was licensed to Tesla.

      The real problem is that nobody's allowed to make big batteries for use in cars because the oil companies bought up all the patents

      Please stop spreading this BS rumor--it's been floating around the "EV community" for long enough, and it's totally untrue.

      Anyone can license those patents, and no, Chevron's not going to build you any unless you want a LOT of them, but it doesn't even matter: No one wants to build NiMH cars anyway, because we have much better cells (Li-ion) now. Even hybrids, which need power (more so than energy) and were the last NiMH holdouts have moved to Lithium.

      This is the reason they have to use 8000 tiny little flashlight batteries in cars instead of a few dozen big ones.

      This is wrong in so many ways it makes my head hurt. First, you're confusing radically-different cell chemistires (NiMH vs. Li-ion). Second, the "flashlight" cells are actually 18650 Li cells, a form factor often used in notebook computers. Lastly, Telsa uses 18650 cells because they are (by a large margin) the best available in terms of energy density [Wh/kg]. If you want heavier or more expensive cells, there are plenty to choose from.

  2. Statistical fallicies by Anonymous Coward · · Score: 5, Insightful

    If we extrapolate this curve and assume everything else remains constant, DOOOOOOOOOM!!!!

    But it gets the clicks, and that's all that matters on the tubes.

    1. Re:Statistical fallicies by jdunn14 · · Score: 3, Interesting

      Seriously: http://xkcd.com/605/

      I bet someone in battery manufacturing is looking as adding capacity now in anticipation of such events. This could be quite an opportunity for some manufacturer with a bit of foresight. As more companies make and sell more electric cars I doubt Tesla will be the only company hunting for more, cheaper, better.

    2. Re:Statistical fallicies by JWW · · Score: 3, Insightful

      Yep. In fact probably many someones.

      The way capitalism works is demand first, then supply shows up. It can't even be done the other way around.

      In fact this large demand is going to be what eventually causes prices for batteries to go down, because, like I said before, many companies are going to get into this business...

    3. Re:Statistical fallicies by paiute · · Score: 4, Informative

      The way capitalism works is demand first, then supply shows up. It can't even be done the other way around.

      Sure it can. A process can generate a lot of some material which nobody currently needs. The manufacturer will then go and look for a market which can use this material and try to develop that market.

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    4. Re:Statistical fallicies by h4rr4r · · Score: 4, Insightful

      There were no smartphones before the iPhone? Really? There was no desire for portable computing?

      There was no demand for cars before Tesla?

      Demand exists before supply. If no one wanted to ever go faster than a horse the car would never have been a success.

  3. Markets, how do they work? by martas · · Score: 3, Funny

    I seem to recall some old English dude saying stuff about supply and demand... But sarcasm aside, isn't it about time we had some tangible breakthroughs in battery tech?

  4. Well... by nitehawk214 · · Score: 5, Funny

    Make more?

    Crisis solved. I will even waive my customary consulting fee.

    --
    I'm a good cook. I'm a fantastic eater. - Steven Brust
    1. Re:Well... by rhsanborn · · Score: 4, Interesting

      This. There are several battery plants that were built in anticipation of a boom in hybrid and EV vehicles during the first spike in oil prices. Once oil prices stabilized, those booms of new EVs never happened, and there are several battery plants that are sitting idle right now. The Dow Kokam plant in Midland could absorb half of the Tesla increase alone. http://www.dowkokam.com/about-dow-kokam/global-capabilities/midland-battery-park/

  5. Do I lack reading comprehensiosn skills? by oodaloop · · Score: 4, Insightful

    So if Tesla doubles production, it would consume the entire world's production of li-ion cells. So the measly 21k cars Tesla produces use half of the world's production already? Maybe I can't read and/or do math though.

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    1. Re:Do I lack reading comprehensiosn skills? by Rob+the+Bold · · Score: 4, Insightful

      So if Tesla doubles production, it would consume the entire world's production of li-ion cells. So the measly 21k cars Tesla produces use half of the world's production already? Maybe I can't read and/or do math though.

      It's not your math, it's the lack of data in TFAs. I can't find the number of cells per Tesla battery in any of the articles, either. Maybe I just got bored paging through. Stupid ADD. Anyway. searching around gives guesses of 7500 to 8000 cells in the top-of-the-line pack. So another 20000 cars would be 160 million more cells. If a laptop uses four to eight cells per battery, that's a lot of laptops worth of cells.

      --
      I am not a crackpot.
  6. Re:18,650? Really? by homsar · · Score: 5, Informative

    18650 is the name of the size of cell. See this table.

  7. Rather Breathless Headline by Rob+the+Bold · · Score: 4, Insightful

    We start with some seriously breathless doom-and-gloom headlines and summary, then reading the articles we find this sort of thing:

    The carmaker's rapid production scale-up has prompted Panasonic to expand capacity, by reopening previously idled plants, while simultaneously committing to build entirely new production lines.

    So prices had been dropping, production had been cut, but now at least one cell maker has restarted idled lines. That doesn't exactly sound like a disaster in the making.

    --
    I am not a crackpot.
  8. price competition via supply shortfall. by goombah99 · · Score: 5, Insightful

    I wonder which has the better profit margin, electronic devices or Tesla? Presumably that decides how this plays out. The interesting thing is that it's going to become a barrier to entry for electric car makers. The one with the highest profit margin can set the price of the batteries above the profit margin of the competition when there is a supply shortfall.

    --
    Some drink at the fountain of knowledge. Others just gargle.
    1. Re:price competition via supply shortfall. by trout007 · · Score: 4, Interesting

      The question to ask is what happens to the price of a laptop and a Tesla if the price of the batteries increases.

      A laptop uses maybe 6 cells which retail on amazon for about $10. So a doubling of prices would at most cost a laptop owner another $10 which is almost in the noise.

      A Tesla if using 2000 times the number would cost about $20k more. That is pretty significant.

      --
      I love Jesus, except for his foreign policy.
    2. Re:price competition via supply shortfall. by Anonymous Coward · · Score: 5, Funny

      JESUS CHRIST it's a li-on, GET IN THE CAR!

    3. Re:price competition via supply shortfall. by timeOday · · Score: 3, Insightful

      Or economies of scale will kick in and the batteries will get a lot cheaper.

    4. Re:price competition via supply shortfall. by Anonymous Coward · · Score: 5, Funny

      The li-on is already in the car! It's a trap!

    5. Re:price competition via supply shortfall. by msauve · · Score: 5, Funny

      Just wait until the new titanium-graphite (TiGr) and beryllium-argon (BeAr) batteries reach the market.

      --
      "National Security is the chief cause of national insecurity." - Celine's First Law
    6. Re: price competition via supply shortfall. by xaxa · · Score: 5, Funny

      Whoosh!

      Tungsten-hydroxy-osmium-hydride? Sounds expensive!

    7. Re:price competition via supply shortfall. by jimbolauski · · Score: 3, Informative

      Ore is defined by the price of the mineral and the cost to dig and refine it. If prices don't go up there simply is not enough ore to mine. Even though Lithium cobalt oxide costs about $30 a kg it's still too expensive to recycle and too risky to mine many mineral deposit locations. At $40 a kilogram many sites could open up and expect a ROI in 10 years. The price right now simply won't allow for mining in many areas that have stringent environmental controls which is why China is one of the largest suppliers. Economies of scale won't be enough to overcome the environmental regulation that are used to control such a dirty mining process.

      --
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      P= W/t
      t=Money
      Money = Work/Knowledge so the less you know the more you make
  9. Re:And, Li-Ion batteries are improving exponential by smith6174 · · Score: 4, Insightful

    Seriously, putting an r-squared value on the chart for apparently FOUR data points? Scientist card revoked.

  10. Re:18,650? Really? by K.+S.+Kyosuke · · Score: 5, Funny

    Basically, they're on their way to consume the li-on's share of Li-Ion cells. Sounds about right!

    --
    Ezekiel 23:20
  11. Perspective is important by wchin · · Score: 5, Informative

    The lithium ion 18650 cylindrical cell production has been dropping as laptop demand has dropped and as laptops are moving to lithium polymer flat pack batteries.

    Panasonic/Sanyo has had to close factories. Originally, Panasonic's plants that were acquired from Sanyo were supposed to be able to produce 300 million cells in their Suminoe plant in Osaka, Japan in just stage 1.

    http://www.eetasia.com/ART_8800603184_765245_NT_5f784554.HTM

    That plant alone, running at full stage 1 capacity could produce enough batteries for 40,000 85kWh Model S's. The demand from Tesla is strong enough that they are expanding production again:

    http://articles.economictimes.indiatimes.com/2013-08-21/news/41433228_1_lithium-ion-batteries-production-line#

    However, it really isn't the Model S or Model X that will have the issue, or even the initial production of whatever Gen 3 car that is coming. The big issue is making enough batteries for millions of EVs, and that will take some planning for the necessary expansion.

    1. Re:Perspective is important by Spoke · · Score: 3, Interesting

      The big issue is making enough batteries for millions of EVs, and that will take some planning for the necessary expansion.

      Luckily all the big manufacturers have been building battery plants - the problem is that automobile manufacturers haven't been building good enough cars around those proposed battery packs to fully utilize those factories.

      A few examples:

      Nissan / AESC: Finished a large battery plant earlier this year in Tennessee thanks to DOE loan. Currently only supplies batteries for the Nissan LEAF (24 kWh battery pack), which sells about 1,600 / month or 20,000 / year in the USA. Maximum capacity of the plant when fully ramped up is claimed to be around 150,000 / year or over 12,000 / month.

      LG Chem: Finished a large battery plant last year in Michigan thanks to DOE loan. Unfortunately, has been sitting idle for some time, though is finally starting to produce batteries for the Chevrolet Volt (16.5 kWh battery pack). Maximum capacity of the plant is claimed to be around 60,000 / year, currently the Volt is selling about 1,600 / month or 20,000 / year in the USA.

      A123: Finished a large battery plant in 2010 in Michigan thanks to DOE loan. Capable of 30,000 battery packs/year. Unfortunately a very large bad bad of batteries delivered to Fisker and Fisker's demise also lead to A123's demise whose assets were bought out. Still operating, and delivering batteries for the Chevrolet Spark EV (20 kWh battery pack). Unfortunately the Spark EV is a low volume vehicle so far only available in a few markets. Launched late June, only sold 130 through July (August sales numbers should be out soon).

      Anyway - my point is that there is plenty of supply out there for lithium batteries right now - there are more plants than just the ones mentioned here - both in the USA and abroad. The competition is tough (see A123's bankruptcy and others, too) so despite low interest loans manufacturers are going under. What's needed is a few more plug-ins with a bit more appear - either more utility or lower price.

      Both Nissan / GM / Tesla have shown that the public will buy electric cars if they are good products and priced right.

      Nissan says they are actually selling all the LEAFs they can make and are currently capacity constrained after a big price drop for the '13 model - they are apparently being conservative in ramping up production capability. Inventory levels support their claims. If Nissan could get at least 25% more range into the car (and perhaps a more neutral package) without increasing the price, I think they could easily sell quite a few more EVs.

      GM needed to drop the price of the Volt - they finally did so for the '14 model and they are saying as a result August will be their best sales result yet. Inventory levels support their claims. If GM could get the Volt drivetrain into a slightly roomier vehicle without sacrificing much efficiency and keeping the price down, I think they could easily sell quite a few more PHEVs.

      Tesla has finally worked through most of the backlog of their USA orders (there's only so many people who can afford $70k+ cars) and are starting to ship product to Europe. They are expecting to stay at maximum capacity for the foreseeable future (over 2,000 Model Ss / month).

  12. Re:Super capacitors by necro81 · · Score: 3, Informative

    [sigh...]

    Super capacitors are awesome, and would dovetail very nicely with Tesla's high-capacity charging stations. But the simple fact is that they are still about an order of magnitude lower in energy density than Li-Ion. Sure, lots of people are looking to improve that, but it is doubtful that Musk is going to (or would even be able to) dump enough R&D money into the field to bring about an automotive "battery" using supercapacitors anytime soon. If he's going to put money into the field at all, it'll probably be to integrate a relatively small amount of supercapacitance into the conventional battery pack to improve the pulse power capability.

  13. The Great Horse-Manure Crisis of 1894 by watermark · · Score: 3, Interesting

    The Great Horse-Manure Crisis of 1894. Writing in the Times of London in 1894, one writer estimated that in 50 years every street in London would be buried under nine feet of manure.

  14. Analogy to Apple by necro81 · · Score: 3, Insightful

    There was a time when there was this thing called the iPod, and it had a small magnetic hard drive inside it. iPods were really big business - hundreds of millions were made. iPods practically cornered the market for 1.8" hard drives for a while. The world did not end.

    More recently, Apple started producing iPods and, later on, entire freaking phones, tablets, and computers that did away with the spinning magnetic discs in favor of flash memory. Apple sold of lot of those, too, and for a long while has consumed a large fraction of the entire world output of flash memory. Lo and behold: world output increased to match demand.

    If anything, these facile comparisons should give Elon Musk an idea: pre-purchase huge swaths of 18650s as a strategic move, just as Apple has done for flash memory and touchscreens over the years. Doing so would ensure the lowest possible price, a consistent supply chain, and make it harder for competitors to enter the market on equal terms.

  15. Re:so glad for the solution by cribera · · Score: 5, Interesting

    Lithium doesn't come from rare earth ores. It's in fact almost on the opposite end of the periodic table, being the first metal (after hydrogen and helium).

    It's mainly found in Bolivia, which is a bit of a problem: Bolivia would like to have a domestic battery industry (higher revenue), instead of exporting raw lithium. The problem? A 20th century socialist for president, who is quite successfully scaring away international investment. As a result, the main exporter is Chile, which has smaller deposits.

    In reality, bolivian government is not allowing transnational companies get the lithium for pennies, as they do in other countries who were servile to transnational power, or as happened in Bolivia before.

    They are investing heavily (Bolivia is still poor, but its economy is growing steadily, while other countries were affected by the world crisis) in their own R&D, and they consider that no matter how long it takes for them to get everything going on, it's better than the alternative that letting trasnational companies get the lionshare of the profits.

    Think about it, 2 alternatives for Bolivia.

    A) Zero pennies now, for getting big profits in the future by controlling its own Lithium production.

    B) Small profits now, letting the corporations get the lionshare forever.

    They chose A, wisely IMO. In fact, that example should be followed by more poor countries, isn't this a good way to stop corporations greed to keep them in poverty while they earn huge profits on the resources of the country?

  16. Re:Lithium. What, do you think, is the name root? by Smidge204 · · Score: 4, Interesting

    I've read there is up to 28 million tonnes (depending on who you ask) of lithium available for commercially viable mining, and the total quantity of lithium on the planet being something like 3 million billion tons (only a fraction is actually accessible, of course). Lithium is about as plentiful as nickel.

    If we go with a conservative 8 grams of Li per 100 Watt-Hours of battery capacity, that 28 million tonnes translates to 355,000,000 megawatt-hours of storage - Enough for nearly six billion 60kWh Tesla vehicles. That's roughly five times as many vehicles that are thought to be on the road on the entire plant today.

    Granted that only a portion of our lithium production goes to batteries, but even if we consider those other uses there is nothing like a shortage of Lithium on the horizon. The bottleneck is entirely production related.

    Plus, unlike oil, lithium is not consumed when used and can be recycled.
    =Smidge=

  17. Re:18,650? Really? by anethema · · Score: 3, Informative

    Ya. Just in case it isn't obvious, 18650 means 18mm Diameter, 65mm length, and 0 at the end indicates a cylindrical cell. AA batteries are 14500 sized, and CR123's are 16340s.

    I use 18650s and 26650s in all my flashlights. Lithium is cheap, bright, and long lasting compared to AA NiMH. Love em!

    --


    It's easier to fight for one's principles than to live up to them.
  18. Re:so glad for the solution by swillden · · Score: 3, Insightful

    A) Zero pennies now, for getting big profits in the future by controlling its own Lithium production.

    B) Small profits now, letting the corporations get the lionshare forever.

    Or maybe C) Zero pennies ever, if some other battery tech replaces Li-ion before they get spun up.

    The smart move would be to sell lithium now for its raw material value while setting up battery production for the future. Don't leave money on the table now while preparing to step up the food chain.

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