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By Arthur Frederick (Fritz) Hasler, PhD, Former Leader of NASA Goddard Space Flight Center Scientific Visualization & Analysis Laboratory, and avid CleanTechnica reader

When Toyota introduced the Prius hybrid in 1997, I was fascinated by the technology and longed to own one — or better, one modified to run a few more miles solely on battery electric power. However, I had a great new Toyota Highlander, a Camry, and no extra money, so another car was not in the cards.

February 21, 2014
2014 Nissan Leaf SV

  • Range 80 miles
  • 24 kWh battery

In 2014, Nissan was offering the Leaf on a two-year lease for $2000 down and $200 per month. I figured it was a no-brainer, I would save at least $100 per month in fuel cost, so I would have a great commuter car for only $100 per month net cost. I leased it from the Ken Garff Nissan in Orem, Utah. I was told the 2014 Nissan Leaf had a range of 83 miles. I got a level 2 charger installed in my garage so that I could get the car fully charged in only four hours.

It was a very nice car, smooth as silk with great acceleration, but problematic for longer trips. SLC International Airport was 86 miles round trip from our house, so you couldn’t just pick someone up at the airport going 75 mph both ways. You would either have to stop and charge in downtown Salt Lake City at the Nissan dealer or drop your speed to 50 miles per hour. And forget about using the heat in the winter or AC in the summer. I spent many trips in the Leaf dressed in my ski boots, ski pants, parka, ski gloves, and wearing a balaclava to keep warm.

I was teaching Alpine skiing at Brighton Ski Resort 37 miles from our home in Lindon. The Leaf would just barely make the 4700 ft elevation change up Big Cottonwood Canyon, and I would limp into the resort on the last few electrons in the battery. The car would regenerate the battery on the way down the canyon, which would take me to the nearest Nissan dealer, where I would charge in order to make it home. Fortunately, later Brighton put in a L2 charger, so I was able to charge enough while I was teaching in order to make it home.

When it came time to go to Wisconsin for the summer, I loaned the Leaf to my son-in-law, who was very pleased to use it to commute to his job in South Salt Lake from his home near us in Utah County. The next summer my son used the car while we were in Wisconsin.

March 14, 2016
2016 Nissan Leaf SV

  • Range 107 miles
  • 30 kWh battery

In 2016, I got the lease extended on my 2014, but Nissan had just come out with a Leaf with 107 miles range and the lease wasn’t too much more expensive. I leased it from Josh Edson, Utah’s star Leaf salesman, at Tim Dahle Nissan on 4526 S State Street in Salt Lake City. Meanwhile, I had solar panels installed on my house, so I was living the dream, driving on sunshine. With the longer range, we could make the round trip to the airport and the ski resort a little more easily. It was also easier to make the 86 mile round trip to Park City Utah, where my daughter lives without L1 charging at her house. However, it was still often necessary to cut the speed and turn off the heat and AC.

Unfortunately, after only two years, I was bitterly disappointed that the Leaf began to lose range, and making those trips into Salt Lake City and the ski resort were just as hard as they were with the 2014 Leaf.

Fritz and his Nissan Leaf, and bike.

May 2, 2018
2018 Nissan Leaf SV

  • Range 151 miles
  • 40 kWh battery
  • Extras: Technology Package, ProPilot Lane Assist, Smart Cruise, Winter Package

I was determined to never go back to a gasmobile and locked into Nissan for a decent deal to get out of my lease. So, I purchased the completely redesigned 2018 Leaf SV with the technology and winter packages. The new Leaf had a range of 151 miles. It was still easier to make the runs into Salt Lake City and the ski resort. We could now also make the 144 mile round trip to Mount Pleasant and Spring City Utah, where my great grandmother had immigrated from Switzerland in 1865. However, that was just at our range limit and we had to drive slowly to make the trip.

The 2018 had smart cruise control, ProPilot lane assist, Apple CarPlay, and a heat pump heater, so we were enjoying a state-of-the art automobile. It was wonderful to have a car that would heat up very quickly in the winter. However, the lane assist was pretty lame — it worked okay on the Interstate highways, but it would lose track on any tight turns. Also, it wouldn’t automatically slow down for tight turns.

Furthermore, I still had a major problem — I couldn’t bear to leave my wonderful new electric car in Utah when we went to Wisconsin for the summer. Even with 151 miles of range, it would have been a 10+ day odyssey to drive the Leaf, likely with some 8 hour charge stops where I couldn’t find a L3 charger. The only option was to hire a car carrier to ship the Leaf to Wisconsin. In 2018, I shipped the Leaf to Wisconsin for the summer.

I was spoiled by L2 charging in Utah, so I brought an electrician from Northern Lights Electric to my home to see if I had 220 volt service in my garage. 30 minutes and $130 later, I had a NEMA 14-50 outlet in my garage. Since the 2018 Nissan Leaf SV came with an EVSE charging cable, I was able to do L2 charging in my Wisconsin garage for only $130. That fall, I shipped the Leaf back to Utah. In 2019, I shipped my Leaf to Wisconsin for the second time. I spent that whole summer scheming on how I could drive the Leaf back to Utah. But …

More range, more tech.

October 22, 2019
2019 Tesla Model 3

  • Range 310 miles
  • 60 kWh battery
  • Extras: Dual Motors, Long Range, Full Self Driving, Superchargers Galore

By this time, my brother had purchased a Tesla Model S and my daughter had purchased a Tesla Model X. From my brother I was aware that Tesla Superchargers made long-distance travel practical in an electric car. If I had a Model 3, I could easily drive the car to Wisconsin. The Model 3 was now available, and with some innovative financing, I was able to swing a dual-motor Model 3 Long Range. As a technology nerd, I even sprang the extra $6000 for Full Self Driving. With my limited fixed retirement income, I knew I wouldn’t have the money to add it later. We drove the Leaf from Wisconsin to the Minneapolis Tesla dealer and traded it in for the Model 3, which we picked up in Salt Lake City after driving home in our Toyota Highlander. Sweet solution — it wasn’t necessary to ship the Leaf back to Utah.

Now we were really living the dream. Our granddaughter spent three hours in the car that first night playing with the infotainment system. The car launched like a rocket and the Autopilot would drive the car automatically up and down in Big Cottonwood Canyon, slowing down automatically for the tight turns. My wife’s favorite thing about the car is Dog Mode, where the car keeps the car at a safe and comfortable temperature for dogs and alerts a passerby that the temperature is safe and the owner will return soon.

All of a sudden, all of our range issues were a thing of the past. We could do the trip to the airport, the trip to my ski resort, and the trip to my daughter’s in Park City without a thought. We could even make quite extended trips into the mountains without a problem. Trips to Arches National Park and Zion National Park were also possible with stops at Superchargers in Price and Beaver. My L2 charger in the garage worked with the adapter and I set the charging max to 80%, because at age 79, I figured this would be my last car and I would keep it for at least 15 years. I want the battery to last.

That Thanksgiving we had a big family reunion in St George in Southern Utah. St George is only 40 miles from Zion National Park, and gorgeous rock walls of red and white petrified sand dunes and slick rock are everywhere. St George is 269 miles from our home in Lindon near Provo and a little farther from Salt Lake City. There is a lot of Tesla traffic between Salt Lake City and St George. That makes the Supercharger in Beaver halfway between a very popular location. We just got the 8th charging station and the next Tesla had to wait at least a few minutes. I was concerned that in the future, with more Teslas being sold every day, that the Beaver Supercharger would soon be overcrowded. In July of 2019, I marveled when Tesla installed a 24 station 250 kW Supercharger station in Las Vegas. It seemed a huge step up from the mostly 4, 6, and 8 stall chargers I had seen up to that point. When we traveled from St George to Salt Lake City in the spring of 2021, we were astonished to see that Tesla had installed 32 (250 kW) stations at the Supercharger in little Beaver between St George and Salt Lake City. No more worries! Tesla is obviously way ahead of the curve, at least in this part of the network.

In 60 years of driving, my only accidents were hitting a car in my blind spot when changing lanes. Now I could just push the turn signal and the car would change lanes automatically, with me knowing that 3 cameras were watching to be sure the lane change was safe. It was also great to have the car automatically pass slow moving vehicles on the freeway and automatically navigate Interstate highway interchanges and exits. However, on the 12 lane Interstate 15 where we live, the reasons for the automatic lane changes were often inscrutable. I would always use the automatic lane assist even in the city if only for a few hundred yards. I have also observed that automatic lane assist will only engage if there are painted lines on the road, but if they, end the car continues to steer automatically even without the painted lines. I also use the stop at stoplights and stop signs feature, but I am very annoyed that I have to approve going through a green light. I am very disappointed that the so called “Feature Complete” Autopilot on city streets is not yet released to me after Elon Musk has been promising it for years, months, weeks, and days.

Long Distance Driving — No Problem

When it came time to drive from Utah to Wisconsin in the spring of 2020, we left the Highlander at home, downsized our baggage to fit in the Model 3, and set off. We were very worried about travel with the Covid pandemic in full swing, so we were handling the Tesla charging cables with disinfectant wipes and wearing N95 masks when we couldn’t avoid going inside to bathrooms and our hotel rooms.

We had no problems with the Superchargers in Wyoming, and we made it to our usual stop in Lusk Wyoming with a Supercharger right across the street from our regular hotel. The second day, we made it to our regular stop in Worthington, Minnesota, again with a Supercharger only a mile from our regular hotel. The third day took us through Minneapolis, MN, and Wausau, WI, to arrive in Three Lakes, WI, in the same number of days as our gas car and with little inconvenience. At 79, I needed to stop every 100 miles or so and the dog needed a break, so by the time we got back, the car was usually charged and ready to go.

I purchased a big electric mountain bike in Tesla Model 3 and had it shipped to Wisconsin. It arrived in broken boxes and with several key components, including the charger, missing. I resolved to not ship the bike again. So, I went to my local hitch installer and had a 2” receiver installed in my Model 3 to use for my bike rack. The receiver works great. I’ve also pulled my 3000 lb ski boat, and with the famous electric motor torque, I can barely feel the heavy trailer behind me. However, putting the bumper back on after the receiver installation has left gaps a little bigger than I would like.

Calamities & Adventures

Our third daughter lives in North Carolina and we owed her a visit. We loaded up the Model 3 in Wisconsin with everything we would need for the trip to NC and then back to Utah, including the big electric bike on the Küat bike rack, and headed east.

Calamity No. 1

Only 50 miles en route, someone was frantically waving at us and pointing to the back of the car. We pulled over to see that my $5000 electric mountain bike had partially slipped back off the rack and the rear wheel was dragging on the pavement. It had worn through the tire and the back wheel was totally ruined. I had failed to fasten the front tire holder on the bike rack properly. I fastened it more securely and had it fixed in NC.

Calamity No. 2

It was now time to make the long trek 2/3 of the way across the country back to Utah. At the time, we didn’t even know it would be a calamity. As we were driving near my daughter’s house in Concord, NC, we had an intense downpour and flash flooding. We were driving at 45 mph with very poor visibility when we ran into water 12” deep. With the spray we looked like a speed boat, but we managed to drive out of the water after about 100 feet. The first hint of a problem came when driving on a back road in Tennessee when we noticed something scraping on the bottom of the car. It didn’t scrape when driving on the smooth pavement of the Interstate, so I foolishly ignored the problem. Later, I notice that the gap between the bumper and the car had expanded. Again, I foolishly ignored the problem. We were in Western Colorado when we went over a bump and then heard the scraping noise again. We stopped to see that the bumper was nearly falling off the car and part of the apron under the car was totally dragging on the pavement. One more bump or rock under the car and the bumper would fall off completely. Miraculously, right there in the middle of no place, a friendly mechanic was there to help us. We took the extension cord that I use for emergency charging and the mechanic’s belt to tie up the bumper, with the cord running through the trunk lid gap. That was enough to get us back to his home in Rifle, Colorado, and an auto parts store where he proceeded to jack up our car and buy enough bolts to refasten the bumper. We got home safely, but we discovered that we had also lost the two front hubcaps, presumably in the floodwater. Our insurance paid for half of the cost of a new underbody apron and bumper, which we had installed by Tesla Service in Salt Lake City.

Calamity No. 3

Driving west in Eastern Colorado approaching Limon we drove into a fierce windstorm. The winds were a sustained 50 mph headwind gusting to over 65 mph. Tumble weeds were blowing across the roads and we were dodging them like going through a gauntlet or obstacle course. Some were 6 ft in diameter and we were alternately braking and accelerating to miss them. I am always very careful about tracking the estimated state of charge at my destination and I always plan to arrive with a 25% battery reserve. Once we passed the flying tumble weeds, I looked at my estimated battery reserve. In the 50 mph head wind, it had dropped to zero. I knew that I would have to drop my speed to 15 mph to reach the charger in Limon. On the Interstate, with poor visibility, that would have been extremely dangerous. I found a big FedEx semi and drafted 15 feet behind him. We were extremely relieved to roll into the Limon Supercharger with 4 miles of range to spare.

Calamity No. 4

Ontonagon in the Upper Peninsula of Michigan is due north of us in Three Lakes, and only 174 miles round trip from us, so it is well within the range of our Model 3 Long Range. My wife loves to enjoy the beautiful endless sand beach on the South Shore of Lake Superior, the largest lake in the world. One time on the way home we noticed that the tire pressure in one tire was very low. In the boonies with no spare tire, it was time to get worried. None of the small UP towns on our route even had a gas station. However, in one we asked where we could get air and they directed us to the fire station, which had an air hose out in front of the station. We filled up and proceeded south, observing that we were losing a pound of pressure every 5 miles. We limped into the bigger town of Eagle River, where we filled it up again and easily made the last 10 miles to our home in Three Lakes. We grabbed our second car and drove the Model 3 five miles back to our local Greg’s car repair shop and left it where Greg could fix it even if it went flat overnight. It was a nail lodged in the tread which he was able to remove and plug. After that incident, we have been carrying an air pump in the frunk in case it happens again.

New Winter Home in St George, Utah

Our daughter purchased an investment home in St George, Utah, and made it available to us for Covid quarantining the winter of 2020–2021. Once again, there was 220 volt service in the garage, so the installation of a NEMA 14-50 outlet in the garage made it possible to have L2 charging for our Model 3 and our daughter’s Model X, since we both had EVSE cables for our cars.

We drove from Utah back to Wisconsin again in the spring of 2021 carrying the electric bike, but now on a Saris bike carrier that holds it more securely. With the bike on the back, we have noticed a significant loss of range. We now stop at every Supercharger on the Interstate, but only have to charge for 20 min to go on to the next charger. We were still able to make the Utah to northern Wisconsin trip in three days, though.

Electric Avenue at the 2021 Three Lakes 4th of July Parade

Twice now we have put together an electric car exhibition at the Three Lakes, Little Bit of Americana, 4th of July Parade. This year we had 6 Teslas: four Model S (Red, White, and Blue), one Model X, and my Model 3. Our electric golf cart led the parade carrying our Electric Avenue sign. The Model X pulled a trailer with a 110-year-old beautifully restored wooden boat formerly powered by steam, but now battery electric. I put my two electric bikes on my Saris bike rack to show off my e-bikes and to illustrate the utility of a receiver-equipped Model 3.

Summary

We are still nuts about our Model 3 after two years and almost 50,000 miles. Our only significant unforced repair has been to replace a squeaky joint in the front suspension system that was covered under the warrantee. We love the entertainment system, which we use to watch Netflix movies on the rare occasions that we need a longer charge. We also love the music streaming where you can ask for nearly any song you can think of and it will play it. We also frequently sing along using the Karaoke feature when we are traveling, using the fantastic sound system. The voice control is usually excellent: you can ask to navigate to almost anything, ask to change the fan locations & speed, ask to change the temperature settings and seat heaters. You can also use it to ask for the song you want to hear.

We are frequently given the thumbs up, usually by young people, and have spent many hours explaining the advantages of EVs to people we encounter. We also frequently exchange tips with Tesla owners we run into at the Superchargers. When we were newbies, other drivers would give us tips, and now we are the ones that share tips with new Tesla owners. When our 6 year old granddaughter is riding in the back seat with my wife, she says: Grandma, let the car drive itself! That’s what I do where ever I go, particularly on long trips. I sit there letting the car drive itself while I watch like a hawk for those rare cases that I need to intervene. It’s particularly nice eating a concrete mixer with a spoon when you need to use both hands.

Solar-powered home.

More info on Dr. Arthur Frederick (Fritz) Hasler:

Research Meteorologist (Emeritus): NASA GSFC

Adjunct Professor: University of Utah Department of Meteorology

Adjunct Professor: Viterbo University On-Line Studies

PSIA L2 Certified Alpine Ski Instructor: Brighton Utah Ski School

Research Meteorologist (Emeritus): NASA GSFC

Adjunct Professor: University of Utah Department of Meteorology

Adjunct Professor: Viterbo University On-Line Studies

PSIA L2 Certified Alpine Ski Instructor: Brighton Utah Ski School Originator, Producer, & Presenter: NASA/NOAA Earth Science Electronic Theater

Former Leader: Goddard Space Flight Center Scientific Visualization & Analysis Laboratory



 


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Upcoming electric Bentley blends 1930s style with 2030s tech

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Upcoming electric Bentley blends 1930s style with 2030s tech

British ultra-luxe brand Bentley is teasing the upcoming, first-ever all electric model that will take it into the 2030s with a new concept car inspired by the iconic 1930 “Blue Train” Speed Six coupe – and it looks fantastic!

More than any other brand, Bentley was defined by its engine. For decades, in fact, the only meaningful mechanical difference between a Rolls-Royce and a Bentley was the 6.75L twin-turbocharged V8 engine under the flying B hood ornament.

That all changed at the dawn of the twenty-first century. Rolls-Royce was acquired by BMW, while Volkswagen took the reins at Bentley, setting both brands on distinct paths. Now, without its own engine, Bentley faces the challenge of proving to discerning buyers that its cars justify a premium over its mechanical cousins at VW, Audi, and Porsche. That’s why the company is looking to it pre-Rolls merger past, all the way back to the legendary 1930 “Blue Train” Speed Six coupe.

Bentley Blue Train EXP 15 concept


EXP 15 concept and 1930 Blue Train; via Bentley.

“Bentley’s then-chairman Woolf Barnato had a Speed Six four-door Weymann fabric saloon by H J Mulliner, which he used to race the Blue Train in 1930,” explains Darren Day, Bentley’s Head of Interior Design. “Meanwhile, he had a unique one-of-one Speed Six coupe being built, with a body by Gurney Nutting. Even though the coupe wasn’t finished when the race took place, it’s that car (the coupe) that’s become associated with it and has since become an iconic Bentley. What we were influenced by is the idea of a three-seat car with a unique window line and super slick proportions used for grand tours.”

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The EXP 15 concept car features a unique, three-door, three-passenger layout under a sweeping, dramatic roofline lifted from the 1930 tourer. “The seat can rotate and you step out, totally unflustered, not trying to clamber out of the car like you see with some supercars,” continued Day, before dropping the biggest hint yet as to who they’re building the car for. “You just get out with dignity and the Instagram shot is perfect.”

Bentley EXP 15 interior


While almost no technical specs have been revealed other than “full electric,” Bentley says its new concept’s innovative interior layout allows passengers to stretch out in comfort alongside accessible storage compartments that can house a bar, hand luggage, or even pets. The EXP 15 even offers tailgate seating for outdoor parties or suburban soccer games.

But, while the new concept is tall, Bentley hopes it manages to offer the commanding driving position and comfort of an SUV while giving off the “vibe” of a classic grand tourer – something Bentley thinks could be the next wave of the luxury car market.

“The beauty of a concept car is not just to position our new design language, but to test where the market’s going,” offers Robin Page, Bentley Director of Design. “It’s clear that SUVs are a growing segment and we understand the GT market … but the trickiest segment is the sedan because it’s changing. Some customers want a classic ‘three-box’ sedan shape, others a ‘one-box’ design, and others again something more elevated. So this was a chance for us to talk to people and get a feeling.”

As before: no specs, no range estimates, and no promises about if and nothing definitive about when the oft-promised all-electric Bentley will finally bow – but this is certain: when it does arrive, it will be big, brash, and fast.

Electrek’s Take


Now that SUVs are everywhere and in every segment, automakers are desperate to explore or open new niches, hoping to find that next “SUV-like” growth segment. As weird as the three-door, three-seat EXP 15’s interior layout is, you have to admit that it’s different. And, for a vehicle that spends 90% of its time with just one person inside it, it might be more than practical enough.

Let us know if you think Bentley has a winner, or just another concept car gimmick on its hands in the comments.

SOURCE | IMAGES: Bentley.


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In rare earth metals power struggle with China, old laptops, phones may get a new life

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In rare earth metals power struggle with China, old laptops, phones may get a new life

A stack of old mobile phones are seen before recycling process in Kocaeli, Turkiye on October 14, 2024.

Anadolu | Anadolu | Getty Images

As the U.S. and China vie for economic, technological and geopolitical supremacy, the critical elements and metals embedded in technology from consumer to industrial and military markets have become a pawn in the wider conflict. That’s nowhere more so the case than in China’s leverage over the rare earth metals supply chain. This past week, the Department of Defense took a large equity stake in MP Materials, the company running the only rare earths mining operation in the U.S.

But there’s another option to combat the rare earths shortage that goes back to an older idea: recycling. The business has come a long way from collecting cans, bottles, plastic, newspaper and other consumer disposables, otherwise destined for landfills, to recreate all sorts of new products.

Today, next-generation recyclers — a mix of legacy companies and startups — are innovating ways to gather and process the ever-growing mountains of electronic waste, or e-waste, which comprises end-of-life and discarded computers, smartphones, servers, TVs, appliances, medical devices, and other electronics and IT equipment. And they are doing so in a way that is aligned to the newest critical technologies in society. Most recently, spent EV batteries, wind turbines and solar panels are fostering a burgeoning recycling niche.

The e-waste recycling opportunity isn’t limited to rare earth elements. Any electronics that can’t be wholly refurbished and resold, or cannibalized for replacement parts needed to keep existing electronics up and running, can berecycled to strip out gold, silver, copper, nickel, steel, aluminum, lithium, cobalt and other metals vital to manufacturers in various industries. But increasingly, recyclers are extracting rare-earth elements, such as neodymium, praseodymium, terbium and dysprosium, which are critical in making everything from fighter jets to power tools.

“Recycling [of e-waste] hasn’t been taken too seriously until recently” as a meaningful source of supply, said Kunal Sinha, global head of recycling at Swiss-based Glencore, a major miner, producer and marketer of metals and minerals — and, to a much lesser but growing degree, an e-waste recycler. “A lot of people are still sleeping at the wheel and don’t realize how big this can be,” Sinha said. 

Traditionally, U.S. manufacturers purchase essential metals and rare earths from domestic and foreign producers — an inordinate number based in China — that fabricate mined raw materials, or through commodities traders. But with those supply chains now disrupted by unpredictable tariffs, trade policies and geopolitics, the market for recycled e-waste is gaining importance as a way to feed the insatiable electrification of everything.

“The United States imports a lot of electronics, and all of that is coming with gold and aluminum and steel,” said John Mitchell, president and CEO of the Global Electronics Association, an industry trade group. “So there’s a great opportunity to actually have the tariffs be an impetus for greater recycling in this country for goods that we don’t have, but are buying from other countries.”

With copper, other metals, ‘recycling is going to play huge role’

Although recycling contributes only around $200 million to Glencore’s total EBITDA of nearly $14 billion, the strategic attention and time the business gets from leadership “is much more than that percentage,” Sinha said. “We believe that a lot of mining is necessary to get to all the copper, gold and other metals that are needed, but we also recognize that recycling is going to play a huge role,” he said.

Glencore has operated a huge copper smelter in Quebec, Canada, for almost  20 years on a site that’s nearly 100-years-old. The facility processes mostly mined copper concentrates, though 15% of its feedstock is recyclable materials, such as e-waste that Glencore’s global network of 100-plus suppliers collect and sort. The smelter pioneered the process for recovering copper and precious metals from e-waste in the mid 1980s, making it one of the first and largest of its type in the world. The smelted copper is refined into fresh slabs that are sold to manufacturers and traders. The same facility also produces refined gold, silver, platinum and palladium recovered from recycling feeds. 

The importance of copper to OEMs’ supply chains was magnified in early July, when prices hit an all-time high after President Trump said he would impose a 50% tariff on imports of the metal. The U.S. imports just under half of its copper, and the tariff hike — like other new Trump trade policies — is intended to boost domestic production.

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Price of copper year-to-date 2025.

It takes around three decades for a new mine in the U.S. to move from discovery to production, which makes recycled copper look all the more attractive, especially as demand keeps rising. According to estimates by energy-data firm Wood Mackenzie, 45% of demand will be met with recycled copper by 2050, up from about a third today.

Foreign recycling companies have begun investing in the U.S.-based facilities. In 2022, Germany’s Wieland broke ground on a $100-million copper and copper alloy recycling plant in Shelbyville, Kentucky. Last year, another German firm, Aurubis, started construction on an $800-million multi-metal recycling facility in Augusta, Georgia.

“As the first major secondary smelter of its kind in the U.S., Aurubis Richmond will allow us to keep strategically important metals in the economy, making U.S. supply chains more independent,” said Aurubis CEO Toralf Haag.

Massive amounts of e-waste

The proliferation of e-waste can be traced back to the 1990s, when the internet gave birth to the digital economy, spawning exponential growth in electronically enabled products. The trend has been supercharged by the emergence of renewable energy, e-mobility, artificial intelligence and the build-out of data centers. That translates to a constant turnover of devices and equipment, and massive amounts of e-waste.

In 2022, a record 62 million metric tons of e-waste were produced globally, up 82% from 2010, according to the most recent estimates from the United Nations’ International Telecommunications Union and research arm UNITAR. That number is projected to reach 82 million metric tons by 2030.

The U.S., the report said, produced just shy of 8 million tons of e-waste in 2022. Yet only about 15-20% of it is properly recycled, a figure that illustrates the untapped market for e-waste retrievables. The e-waste recycling industry generated $28.1 billion in revenue in 2024, according to IBISWorld, with a projected compound annual growth rate of 8%.

Whether it’s refurbished and resold or recycled for metals and rare-earths, e-waste that stores data — especially smartphones, computers, servers and some medical devices — must be wiped of sensitive information to comply with cybersecurity and environmental regulations. The service, referred to as IT asset disposition (ITAD), is offered by conventional waste and recycling companies, including Waste Management, Republic Services and Clean Harbors, as well as specialists such as Sims Lifecycle Services, Electronic Recyclers International, All Green Electronics Recycling and Full Circle Electronics.

“We’re definitely seeing a bit of an influx of [e-waste] coming into our warehouses,” said Full Circle Electronics CEO Dave Daily, adding, “I think that is due to some early refresh cycles.”

That’s a reference to businesses and consumers choosing to get ahead of the customary three-year time frame for purchasing new electronics, and discarding old stuff, in anticipation of tariff-related price increases.

Daily also is witnessing increased demand among downstream recyclers for e-waste Full Circle Electronics can’t refurbish and sell at wholesale. The company dismantles and separates it into 40 or 50 different types of material, from keyboards and mice to circuit boards, wires and cables. Recyclers harvest those items for metals and rare earths, which continue to go up in price on commodities markets, before reentering the supply chain as core raw materials.

Even before the Trump administration’s efforts to revitalize American manufacturing by reworking trade deals, and recent changes in tax credits key to the industry in Trump’s tax and spending bill, entrepreneurs have been launching e-waste recycling startups and developing technologies to process them for domestic OEMs.

“Many regions of the world have been kind of lazy about processing e-waste, so a lot of it goes offshore,” Sinha said. In response to that imbalance, “There seems to be a trend of nationalizing e-waste, because people suddenly realize that we have the same metals [they’ve] been looking for” from overseas sources, he said. “People have been rethinking the global supply chain, that they’re too long and need to be more localized.” 

China commands 90% of rare earth market

Several startups tend to focus on a particular type of e-waste. Lately, rare earths have garnered tremendous attention, not just because they’re in high demand by U.S. electronics manufacturers but also to lessen dependence on China, which dominates mining, processing and refining of the materials. In the production of rare-earth magnets — used in EVs, drones, consumer electronics, medical devices, wind turbines, military weapons and other products — China commands roughly 90% of the global supply chain.

The lingering U.S.–China trade war has only exacerbated the disparity. In April, China restricted exports of seven rare earths and related magnets in retaliation for U.S. tariffs, a move that forced Ford to shut down factories because of magnet shortages. China, in mid-June, issued temporary six-month licenses to certain major U.S. automaker suppliers and select firms. Exports are flowing again, but with delays and still well below peak levels.

The U.S. is attempting to catch up. Before this past week’s Trump administration deal, the Biden administration awarded $45 million in funding to MP Materials and the nation’s lone rare earths mine, in Mountain Pass, California. Back in April, the Interior Department approved development activities at the Colosseum rare earths project, located within California’s Mojave National Preserve. The project, owned by Australia’s Dateline Resources, will potentially become America’s second rare earth mine after Mountain Pass. 

A wheel loader takes ore to a crusher at the MP Materials rare earth mine in Mountain Pass, California, U.S. January 30, 2020. Picture taken January 30, 2020.

Steve Marcus | Reuters

Meanwhile, several recycling startups are extracting rare earths from e-waste. Illumynt has an advanced process for recovering them from decommissioned hard drives procured from data centers. In April, hard drive manufacturer Western Digital announced a collaboration with Microsoft, Critical Materials Recycling and PedalPoint Recycling to pull rare earths, as well as copper, gold, aluminum and steel, from end-of-life drives.

Canadian-based Cyclic Materials invented a process that recovers rare-earths and other metals from EV motors, wind turbines, MRI machines and data-center e-scrap. The company is investing more than $20 million to build its first U.S.-based facility in Mesa, Arizona. Late last year, Glencore signed a multiyear agreement with Cyclic to provide recycled copper for its smelting and refining operations.

Another hot feedstock for e-waste recyclers is end-of-life lithium-ion batteries, a source of not only lithium but also copper, cobalt, nickel, manganese and aluminum. Those materials are essential for manufacturing new EV batteries, which the Big Three automakers are heavily invested in. Their projects, however, are threatened by possible reductions in the Biden-era 45X production tax credit, featured in the new federal spending bill.

It’s too soon to know how that might impact battery recyclers — including Ascend Elements, American Battery Technology, Cirba Solutions and Redwood Materials — who themselves qualify for the 45X and other tax credits. They might actually be aided by other provisions in the budget bill that benefit a domestic supply chain of critical minerals as a way to undercut China’s dominance of the global market.

Nonetheless, that looming uncertainty should be a warning sign for e-waste recyclers, said Sinha. “Be careful not to build a recycling company on the back of one tax credit,” he said, “because it can be short-lived.”

Investing in recyclers can be precarious, too, Sinha said. While he’s happy to see recycling getting its due as a meaningful source of supply, he cautions people to be careful when investing in this space. Startups may have developed new technologies, but lack good enough business fundamentals. “Don’t invest on the hype,” he said, “but on the fundamentals.”

Glencore, ironically enough, is a case in point. It has invested $327.5 million in convertible notes in battery recycler Li-Cycle to provide feedstock for its smelter. The Toronto-based startup had broken ground on a new facility in Rochester, New York, but ran into financial difficulties and filed for Chapter 15 bankruptcy protection in May, prompting Glencore to submit a “stalking horse” credit bid of at least $40 million for the stalled project and other assets.

Even so, “the current environment will lead to more startups and investments” in e-waste recycling, Sinha said. “We are investing ourselves.”

MP Materials CEO on deal with the Defense Department

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LiveWire gives surprise unveil of two smaller, lower-cost electric motorcycles

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LiveWire gives surprise unveil of two smaller, lower-cost electric motorcycles

LiveWire, the electric motorcycle company that was spun out of Harley-Davidson several years ago, has just shown off two fun-sized electric motorcycles designed to make powered two-wheelers more accessible to new riders, both physically and financially.

The company took to HD Homecoming, a motorcycle festival in Milwaukee, to give a surprise unveiling of the new bikes.

The bikes, which wear what look to be smaller 12″ tires and offer a barely 30″ (76 cm) seat height, are smaller and nimbler than anything we’ve seen from LiveWire before.

But that doesn’t mean they can’t perform. These aren’t some 30 mph (48 km/h) mopeds. LiveWire confirmed that early testing shows respectable performance figures of around 53 mph (85 km/h) speeds and 100 miles (160 km) of range from the pair of removable batteries.

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I’m assuming that range is measured at a lower urban speed, but these appear to be purpose-built to give riders the capability to ride where and how they want at a much more affordable price than LiveWire has ever offered.

Showing off both a trail and a street version, the LiveWire seems to be covering all of its bases.

“The trail model is intended for riding backyards, pump tracks, or even out on the ranch or campgrounds,” the brand explained. “The street model is perfect for urban errands, new riders, mini-moto fans, and anyone looking for a new hobby in the form of a readily customizable, approachable electric moto experience.”

LiveWire hasn’t shared any pricing details yet, and the two models are understood to still be in their development phase, but the advanced stages of the designs mean we likely won’t have to wait too much longer.

And with most of LiveWire’s current electric motorcycle models in the $16k- $17k, these bikes could conceivably cost less than half of that figure, changing the equation for young riders who can’t afford a luxury ride.

Electrek’s Take

Of course, they had to do this unveiling at the exact time that I was banging out a multi-thousand-word treatise bemoaning the fact that LiveWire hadn’t launched any smaller models yet. Hmmm, maybe it’s time for an article about how the e-bike industry needs a single battery standard.

Anyway, I’m all-in on this! I can’t even describe how excited this news makes me! This is an important step for LiveWire’s growth because the kind of folks who are drawn to electric motorcycles are often a different market than that sought by traditional legacy motorcycle manufacturers. LiveWire’s existing models are impressive, both in their extreme performance and their design, but they’re still powerhouses that provide more kick than most riders probably need.

These new mini e-motos could be exactly what new riders are looking for. Consider all the teens and young adults ripping it up on Sur Rons in towns across the US right now. Those Sur Rons aren’t street-legal bikes and they were never meant for the riding they’re most commonly being used for. But a street bike in a fun little Grom form factor like LiveWire is showing off? It could scratch that itch and also provide riders with the safety and support of a motorcycle company that comes from a storied history of over 100 years of motorcycle design, all from a new brand like LiveWire that speaks young riders’ language.

And that trail version – same thing. It’s going to offer the fun off-road riding that so many are looking for, yet do it in a well-designed package that isn’t just produced by some nameless factory in China trying to eke out the best profit margin.

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