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In order to qualify for the $7,500 tax credit, the Biden administration’s Inflation Reduction Act (IRA) requires a proportion of battery minerals in EVs to be extracted or processed in the US or free-trade partner countries. But a lot of automakers simply aren’t prepared for that requirement.

Electrek spoke with Megan O’Connor, cofounder and CEO of Nth Cycle, a Beverly, Massachusetts-based metals processing tech company, about how her company can help EV manufacturers address this challenge quickly.

Electrek: How will the IRA positively impact the critical mineral supply chain?

Megan O’Connor: The IRA is the most ambitious climate policy we’ve ever seen in the US and arguably one of the more aggressive policies in the world. It provides strong incentives for the usage of critical minerals that are refined or recycled domestically. We’re calling this the new “compliant supply” of minerals like nickel and cobalt.

Unfortunately, there’s not enough compliant supply today to meet the demand for critical minerals in North America to build electric vehicles. From 2024 to 2028, there’s going to be a major imbalance between compliant supply and demand.

There aren’t enough end-of-life EV batteries to allow recycling at a scale that can bridge the gap, and permitting new mines in North America is a five-plus-year process. We need to move quicker and responsibly on new mining opportunities, and look for new existing sources of critical minerals that can be recycled at home.

Electrek: What’s next for the clean energy transition when it comes to domestic mineral supply?

Megan O’Connor: Flexibility in refining is the next key factor in developing a compliant supply of critical minerals at home. Adding flexibility to the quality and consistency of ores and recycled materials that can be refined at home increases our ability to keep mined ores and recycled metals here when they’re currently shipped overseas for processing.

Additionally, most recyclers today focus on processing end-of-life or manufacturing scrap batteries for critical mineral sources. We expect to see companies and technologies go beyond batteries to find other sources of critical minerals already in circulation at home. Growth of new technologies and market expansion will be needed to address the imbalance between compliant supply and demand.

Electrek: How will domestic manufacturers like VW in Tennessee be able to rectify the issue of mineral components not meeting IRA requirements?

Megan O’Connor: By partnering with Nth Cycle, VW would be able to meet compliance in months, not years.

Electrek: How is Nth Cycle helping to meet the IRA requirements in the electrification transition?

Megan O’Connor: Nth Cycle produces a mixed hydroxide precipitate (MHP), which contains nickel and cobalt. Production of MHP through laterite ore refining is growing in popularity as a precursor chemical for battery cathode manufacturers.

However, 81% of today’s MHP supply is refined in Indonesia, by Chinese companies, through a carbon-intensive hydrometallurgy refining process called HPAL (high-pressure acid leaching). This HPAL-based supply of MHP is harmful to the environment, and as a foreign supply, is not a compliant supply of critical minerals for domestic battery manufacturing under the recently passed Inflation Reduction Act.

Nth Cycle customers can have confidence in a domestic supply of MHP that meets compliance standards for EV tax credits under the Inflation Reduction Act while dramatically reducing the carbon footprint of domestic refining.

We can bring additional compliant supply to the market and close the supply/demand gap of 150,000 tonnes of Ni (equivalent to 340 GWh of batteries) over the next five years.

If we were fully deployed right now, Nth could find 100kt tonnes of Ni per year from within the US that isn’t currently being recycled. We estimate a further shortage of at least 50kt of Ni per year.

Our electro-extraction technology is 92% lower emissions than traditional refining processes in mining today and 44% lower emissions than today’s best-in-class recycling technologies. This is third-party verified.

Read more: Here’s every electric vehicle that qualifies for the current and upcoming US federal tax credit

Photo: Megan O’Connor, Nth Cycle


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Kia’s new Syros SUV is going electric as a low-cost Hyundai Inster EV twin

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Kia's new Syros SUV is going electric as a low-cost Hyundai Inster EV twin

Kia introduced its new Syros SUV last week. Although it was launched with a gas-powered engine, Kia plans to launch the all-electric version soon. The new Kia Syros EV will share underpinnings with the Hyundai Inster EV as its latest low-cost electric model.

What we know about the upcoming Kia Syros EV

India’s EV market is expected to surge over the next few years. In 2024, the India EV market is projected to be valued at around $24 billion. That number is expected to reach nearly $118 billion by 2032.

Kia is looking to take advantage of the transition. After launching its first vehicle (Seltos) in India in 2019, Kia is already one of the top 10 auto manufacturers in the region.

The Korean auto giant has added several models to its lineup, including the Sonet, Carnival, Caren, and electric EV6 and EV9 SUVs.

Just last week, the Kia Syros made its global debut. Kia calls the compact SUV “revolutionary,” but there’s one problem: it only has two gas-powered engine options. That will soon change. According to Autocar India, Kia will launch the Syros EV in India in early 2025.

Kia-Syros-EV
Kia Syros SUV (Source: Kia)

Although no other details were confirmed, the Kia Syros EV will share its K1 platform with the Hyundai Inster EV. Hyundai’s compact electric crossover has two battery options, 42 kWh and 49 kWh, good for 300 km (186 mi) to 355 km (220 mi) range on the WLTP cycle.

In Europe, the Inster EV starts at around $30,000. In Korea, the electric crossover is known as the Casper Electric, and prices, including incentives, start around $20,000.

Hyundai-Casper-EV-Cross
Hyundai Casper Electric (Inster EV) models (Source: Hyundai)

Kia’s new electric SUV is expected to start in the price range of Rs 15 lakh-20 lakh (ex-showroom), or around $17,500 to $23,500.

Despite the difference in powertrain, the electric version is expected to have the same styling and features as the gas-powered models. Kia expects between 50,000 and 60,000 in sales between the upcoming electric Carens and Syros EV models by 2026.

The company is launching a series of more affordable, mass-market EVs globally, including the EV3, EV4, and EV5, to secure its spot in the industry as it shifts to electric vehicles.

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Hyundai’s all-solid-state EV batteries are on the verge of a major milestone

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Hyundai's all-solid-state EV batteries are on the verge of a major milestone

Hyundai is about to take the next steps as it preps to launch production of its “game-changing” all-solid-state batteries. The new EV battery tech promises a longer driving range, faster charging, and significantly higher energy density. Here’s what to expect.

When are Hyundai’s all-solid-state EV batteries coming?

Last June, Hyundai Motor CEO Chang Jae-hoon revealed a massive $7.3 billion (9.5 trillion won) investment to advance electric vehicle battery development over the next decade.

Hyundai plans to develop various EV batteries, including LFP, NCM, and all-solid-state, to cover a wide range of segments. According to sources familiar with the matter (via TheKoreanCarBlog), Hyundai’s all-solid-state EV batteries are about to hit a significant milestone.

On December 23, industry sources claimed Hyundai was almost done establishing an all-solid-state battery production demo line.

An official close to the project said the equipment for individual processes is almost complete. Now, only the logistics automation portion remains.

Hyundai plans to begin testing electric vehicles with all-solid-state batteries by 2025. By the end of the decade, mass production is scheduled to start.

Hyundai's-all-solid-state-EV-batteries
2025 Hyundai IONIQ 5 (Source: Hyundai)

The production line is at Hyundai’s Uiwang Research & Development Center in Korea. Hyundai has 22 joint research projects across four divisions, including lithium metal batteries, solid-state batteries, battery management systems, and battery process technology. Of these, 14 will be related to lithium metal and solid-state batteries.

Hyundai said the initiatives will “pave the way for South Korea to become one of the world’s leading battery technology houses.”

Hyundai's-all-solid-state-EV-batteries
Hyundai IONIQ 9 three-row electric SUV (Source: Hyundai)

In September, Hyundai and Kia launched a joint project to develop a precursor for LFP battery cathode material for upcoming lower-priced EV models. Hyundai plans to launch EVs with LFP batteries developed in-house in 2025.

The news comes after Honda unveiled its all-solid-state battery demo production line just last month. Honda also plans to launch EVs powered by the new battery tech by 2030.

Hyundai-Casper-Electric
Hyundai Casper Electric, known as the Inster EV overseas (Source: Hyundai)

Factorial, which teamed up with Mercedes-Benz, announced its “Solstice” all-solid-state battery cells have been scaled to 40Ah capacity, a new milestone. With “breakthrough” energy density of up to 450 Wh/kg, Factorial claims its battery tech can boost EV range by up to 80%, or around 600 miles.

Electrek’s Take

With the promise of unlocking more range and faster charging at a much higher energy density, many carmakers and other companies are rushing to unlock all-solid-state EV batteries.

Global battery leaders like CATL, BYD, and Samsung SDI, as well as carmakers like Toyota, Mercedes-Benz, and Hyundai, are advancing the new technology. However, concerns over safety and manufacturing hurdles remain a challenge.

According to the latest SNE Research figures, China’s CATL remains the global EV battery leader with a commanding 36.8% share of the market through the first ten months of 2024. BYD was second with a 16.8% share, while Korea’s LG Energy placed third with an 11.8% share.

Will the next generation of EV batteries shake up the list? Hyundai hopes to make its mark with a new all-solid-sate EV battery production pilot line that will be coming online soon.

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BYD’s new EV plant in Brazil suddenly halted over ‘slavery’ worker conditions [Update]

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BYD's new EV plant in Brazil suddenly halted over 'slavery' worker conditions [Update]

Construction at BYD’s new EV plant in Brazil was suddenly halted Monday after authorities found Chinese workers in “slavery-like” conditions. The workers were hired in China by another firm, and BYD has since cut ties. BYD and the firm are now saying the term “slavery” was unjustly used, and some translations may have been misunderstood.

Why construction at BYD’s EV plant in Brazil is halted

Updated 12/26/24: This article has been updated with the latest information, including a statement from Jinjiang Group and comments from BYD’s general manager of public relations, Li Yunfei. Read more below.

According to a statement from the Public Ministry of Labor (MPT), 163 workers at the construction site of BYD’s new EV plant in Salvador, Brazil, were “being held in conditions analogous to slavery.”

Construction on the site was halted on Monday after the findings. According to the authorities, Jinjiang Group, one of the contractors BYD hired to build the new EV plant, hired the workers in China.

BYD released a statement saying it has cut ties with Jinjiang and is assisting the victims as it works with Brazilian authorities. All workers will be transferred to hotels. They will not be able to work and will have their contracts terminated.

Alexandre Baldy, senior vice president of BYD Brazil, said the company remains “committed to full compliance with Brazilian legislation, especially with regard to the protection of workers’ rights and human dignity.”

BYD's-EV-plant-Brazil-halted
BYD Dolphin Mini (Seagull) launch in Brazil (Source: BYD)

The MPT statement detailed the extreme “slavery-like” worker conditions. For example, they had one bathroom for every 31 workers, forcing them to wake up at 4 am to get in line to be ready for work at 5:30 am. They slept without mattresses on the bed, and the kitchens operated in “alarming conditions.”

If a worker quit after six months, they would leave the country without any pay after factoring in the cost of a round-trip airplane ticket.

BYD-Shark-Brazil
BYD Shark PHEV pickup (Source: BYD)

BYD said it has held a “detailed review” over the past few weeks. The Chinese EV giant asked Jinjiang several times to improve the conditions.

A joint virtual hearing of the MPT and MTE is scheduled for December 26. The MPT said the need for new “on-site inspections” has not been ruled out. BYD’s new EV plant is set to begin production next year. Check back soon for more updates on the situation.

Update 12/26/24: Jinjian Group said the portrayal of its employees working in “slavery-like” conditions was inconsistent, and some of the translations may have been misunderstood.

“Being unjustly labeled as ‘enslaved’ has made our employees feel that their dignity has been insulted and their human rights violated, seriously hurting the dignity of the Chinese people,” Jinjiang said in a social media post (via Reuters). The company issued a joint letter to issue an apology.

BYD’s general manager of public relations, Li Yunfei, reposted the statement. Li added that “foreign forces” and some other members of the media were “deliberately smearing Chinese brands.

Mao Ning, a spokesperson for China’s foreign ministry, said the Chinese embassy in Brazil was in talks with leaders in the region to verify the accusations.

BYD is already a top-selling EV brand in Brazil. In October, it launched its first pickup, the Shark PHEV. The pickup is BYD’s sixth vehicle in Brazil, joining other popular models like the Dolphin Mini (Seagull), Yuan Plus, and Dolphin.

Once up and running, which was expected later this year or early 2025, BYD’s Brazil plant will have an annual production capacity of 150,000 vehicles.

Source: Bloomberg, Brazil Public Ministry of Labor

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