Researchers figured out how to make electric car batteries… from coal?!
Researchers from the Oak Ridge National Laboratory have figured out a way to change the dirtiest fuel out there, coal, into materials to help build batteries for new clean vehicles.
The new process turns coal into graphite, which is an important component in electric car batteries. Graphite is used in the anode, which is the negatively charged end of the battery.
While we hear a lot about various other battery materials, such as lithium and cobalt, those materials actually occur in relatively lower quantities in electric car batteries.
The most common material in these batteries is actually graphite (see an infographic here, though this is for NMC-type batteries), so it’s important to ensure that there is a large supply of this material anywhere batteries need to be built.
And one of those places is in the US – thanks to President Joe Biden’s EV policies, there have been hundreds of billions in investment and hundreds of thousands of jobs brought to American manufacturing, largely in the form of battery plants to ensure that vehicles with modern technology will be made right here in America. Those policies also focused on ensuring onshored or “friend-shored” critical mineral supply for battery materials, such as graphite.
But there’s a problem: a majority of the world’s graphite comes from China. While this isn’t necessarily a problem in and of itself, it’s always better to have multiple sources for any particular material, so that one entity can’t throw their weight around if they see an opportunity. And given the anti-China saber-rattling that a certain treasonous reality TV host regularly engages in, it’s entirely possible that global tensions could result in disruption of graphite supply chains, which could then jeopardize the aforementioned burgeoning US EV manufacturing industry (which that same reality TV host/convicted felon seems determined to ensure does not flourish).
So, in come researchers from Oak Ridge National Laboratories, who figured out a way to turn something that America still has a lot of – coal – into graphite.
It’s not too big of a leap, as graphite is a form of carbon and coal is also mostly carbon. But ORNL’s process takes impurities in coal and removes them to create material that is suitable for a battery anode.
Other methods to create synthetic graphite exist, but require more time, more cost and higher temperatures. The new process is estimated to cost 13% less than the old Acheson process, according to an analysis by ORNL researcher Prashant Nagapurkar.
In the ORNL process, if the electricity is green, the whole process is green. Especially because coal historically has this reputation as ‘dirty,’ a particularly important next step is to track emissions from the entire supply chain through the manufacturing process. This could demonstrate that it is indeed a greener option to manufacture graphite from coal.
–Prashant Nagapurkar, ORNL R&D associate
Better yet, the process doesn’t just work on coal straight out of the ground (which is where coal belongs and should stay) – it also works on coal waste like fly ash, the leftovers of previous coal mining efforts, of which there are over a hundred million tons of this hazardous waste strewn about the country. Thankfully, most of this is on the surface and won’t require further mining to get to.
Researchers say that the process could help to clean up that waste, and give it a use in powering modern vehicles. They estimate that the amount of waste in the US would be enough to provide around 30% of the graphite needed for EV batteries between now and 2050.
The process doesn’t need to be used only on coal, though. Project lead Edgar Lara-Curzio explained to Electrek how it could have potential applications on other sources of carbon:
However, while this particular project focuses on finding a positive use for coal waste, the electrochemical graphitization technology that we are scaling up can be used with other amorphous carbon sources. Once we get rid of waste coal – which would be a major environmental restoration achievement in itself – biomass (e.g., dead vegetation), petroleum, or other carbon sources could be used to manufacture graphite using the same process.
For example, methane pyrolysis, which can be used to produce hydrogen, generates solid carbon as a byproduct, which could be electrochemically graphitized for lithium-ion battery applications. This technology offers the benefit of strengthening domestic supply chains for graphite rather than relying on graphite mined and processed in foreign countries, many of which have much weaker environmental and worker protections.
The ORNL project was done in collaboration with Ramaco Carbon, a Wyoming-based company that owns multiple coal mines and provides coal for steelmaking. Ramaco says that its guiding principle is “coal is too valuable to burn.” Its focus is to find uses for coal that replace petroleum as a feedstock for various chemical and material processes at what it says will be a much lower cost.
Electrek’s Take
At first glance, this seems like some really great research. It onshores graphite supply, offers some scalable competition globally to diversify battery material sources, can be used on old waste, and is cheaper than existing processes.
But it also feels a little sketchy, because what we need to be focusing on is keeping carbon in the ground.
When we take carbon out of the ground, we sure do have a tendency to burn it, which means it ends up in the air, which is bad. Currently the air is 423ppm carbon, which is higher than the 280-350ppm range that represents a proper balance for current life on Earth. This means we don’t need to be taking carbon out of the ground, we need to be putting it back in the ground – and a lot of it.
So, any new process that might make us look at that carbon in the ground and think of another way that we might use it is suspect.
At least in this instance, it’s being proposed by a company that owns coal mines not for burning, but for finding other uses. So they might not use this as an excuse to burn more coal. Which is nice.
However, there has also been a significant push lately for coal-free steel, led by companies like SSAB in Sweden. Coal-based steelmaking (like that which Ramaco provides coal for) is linked to nearly a thousand deaths, $13 billion in healthcare costs and hundreds of thousands of lost school and work days annually in the US.
Given that this research was done in collaboration with a company that provides coal for that same dirty process, it gives us some pause. The process of turning coal into batteries will be cleaner than simply burning coal into the air, and graphite is potentially recyclable and usable long-term in multiple generations of electric car batteries, but it’s hard to shake the fact that coal is one of the most-polluting substances humans have available to us.
So, would we be giving ourselves more reasons to take coal out of the ground with this process? Even though researchers point out that coal waste can be used in this process, what if companies find out that it’s more difficult or costly to process the waste than it is to dig up new coal?
Given that we stubbornly refuse to impose the real price of this pollution on the companies that cause it, it’s entirely possible that coal mines will figure out a way to use this to justify their continued operation (especially whenever a republican administration, who have routinely shown themselves to be hostile to human health and too cozy with the coal industry, finds itself in charge).
So while new science is never a bad thing, this strikes me as something that we should keep an eye on. Cleaning up the environmental disaster of stranded coal waste is a fantastic usage, but lets not let this forestall the rapid shutting down of coal mines in this country.
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For years, Tesla has been the go-to EV recommendation for “normals” looking for a painless, low-effort experience from their first electric cars. In light of questionable recalls and its CEO’s recent involvement in controversial politics, however, people are starting to distance themselves from the trailblazing company.
All that begs the question: what should we recommend to EV noobs now?
Despite early quality issues and ongoing service headaches, the groundbreaking S3XY lineup of EVs have always had a secret weapon in the form of the Tesla Supercharger network.
That network of dependable high-speed chargers, paired with solid app integration that makes it easy for Tesla drivers to find available chargers just about anywhere in the US, gave the brand a leg up – but no more. By opening up the Supercharger network to brands like Ford, Hyundai, Kia, and others, Tesla has given away its biggest competitive advantage.
Add in charging and route-planning apps like Chargeway, that make navigating the transition from CCS to NACS easier than ever with its intuitive colors and numbers and easy on/off switch for vehicles equipped with NACS adapters, and it feels like the time is right to start suggesting alternatives to the old EV industry stalwarts. As such, that’s exactly what I’m going to do.
Here, then, are my picks for the best Tesla S3XY (and Cybertruck) alternatives you can buy.
Less Model S, more Lucid Air
Developed by OG Tesla Model S engineers with tunes from Annie Get Your Gun playing continuously in their heads, the Lucid Air promises to be the car Tesla should and could have built, if only Elon had listened to the engineers.
With panel fit, material finish, and overall build quality that’s at least as good as anything else in the automotive space, the Lucid Air is a compelling alternative to the Model S at every price level – and I, for one, would take a “too f@#king fast” Lucid Air Sapphire over an “as seen on TV” Model S Plaid any day of the week. And, with Supercharger access reportedly coming later this quarter, Air buyers will have every advantage the Supercharger Network can provide.
HONORABLE MENTIONS
Less Model 3, more Hyundai IONIQ 6
Hyundai has been absolutely killing it these days, with EVs driving record sales and new models earning rave reviews from the automotive press. Even in that company the IONIQ 6 stands out, with up to 338 miles of EPA-rated range and lickety-quick 350 kW charging available to make road tripping easy – especially now that the aerodynamically efficient IONIQ 6 has Supercharger access through a NACS adapter (the 2026 “facelift” models get a NACS port as standard).
The company’s sole electric sedan hasn’t seen the same sales success as IONIQ 5, of course – but that has more to do with America’s insatiable lust for crossovers and SUVs than any shortcoming inherent in the IONIQ 6 itself. All the same, Hyundai is helping dealers clear out its remaining 2024 and ’25 models with 0% financing for up to 48 months through June 2nd.
HONORABLE MENTIONS
Less Model X, more Volvo EX90
Once upon a time, Mrs. Jo Borrás and I were shopping three-row SUVs and found ourselves genuinely drawn to the then-new Model X. Back then it was the only three-row EV on the market, but it wasn’t Elon’s antics or access to charging, or even the Model X’s premium pricing that squirreled the deal. It was the stupid doors.
We went with the similarly new Volvo XC90 T8 in denim blue, and followed up the big PHEV with a second, three years later, in Osmium Gray. When it’s time to replace this one, you can just about bet your house that the new 510 hp EX90 with 310 miles of all-electric range will be near the top of the shopping list.
HONORABLE MENTIONS
Less Model Y, more Kia EV6
If half the fun of driving a Model Y is terrifying your passengers with its straight-line speed, then the Kia EV6 has to be a serious contender for a replacement.
The sporty EV6 GT made its global debut by drag racing some of the fastest ICE-powered cars of the day, including a Lamborghini, Mercedes-AMG GT, a Porsche, even a turbocharged Ferrari – and it beat the pants off ’em. Combine supercar-baiting speed with an accessible price tag, NACS accessibility, $10,000 in customer cash on remaining 2024 models ($3,000 on 2025s) and just a hint of Lancia Stratos in the styling, the EV6 is tough to beat.
HONORABLE MENTIONS
Less Cybertruck, more therapy
It’s not bulletproof, it’s not easy to upfit, it shouldn’t be used for towing, and it won’t win in a straight fight against a vinyl picket fence. By just about every standard “truck” metric, the Tesla Cybertruck falls short against the competition from Chevrolet, Ford, and Rivian. On a more subjective front, the Cybertruck has become a symbol for a conservative movement that is (depending on your point of view) either making America great again or plunging a once-great democracy into an era of fascist oligarchy and widespread stupidity.
In short, it’s probably best to skip the CT.
If you disagree with that statement and feel like driving a new Tesla Cybertruck is the key to happiness, I’m not sure an equally ostentatious GMC Hummer EV or more subtle Rivian R1T will help you scratch that particular itch – but maybe therapy might!
HONORABLE MENTIONS
Original content from Electrek.
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Republicans launched multiple attacks against EVs, clean air and American jobs this week, at the behest of the oil industry that funds them. These attacks won’t be successful, and EVs will continue to grow regardless, and inevitably take over for outdated gasoline vehicles.
However, these republican attacks on EVs will still have some effect: they will diminish the US auto industry globally, leading to job losses and surrendering one of the jewels in the crown of American industry to China, where there is no similar effort to destroy its own domestic EV industry.
Republican attacks on clean air this week included moves to block funding that has led to a renaissance in US manufacturing and also to illegally block clean air laws. They also moved forward with a procedural step towards increasing US fuel costs by $23B, an effort which the former reality TV contestant posing as the head of the DOT announced in January.
These moves shouldn’t be a big surprise – republicans have opposed clean air and American jobs for many years now, and they’re doing it because they want to maintain the bribes they get from the oil industry.
But they should inspire worry for Americans, because they will only harm the country’s domestic manufacturing base in the face of a changing auto industry.
Republicans keep trying to kill clean cars
The last time a republican occupied the the White House, we saw similar efforts to try to raise fuel and health costs for Americans, and to block superior EV technology from flourishing. That didn’t work in the end, and EVs continued to grow both during that period and after.
All the while, fossil fuels have maintained their privileged policy position, being allowed to pollute with impunity and costing the US $760 billion per year in externalized costs. Much of that subsidy is accounted for in the cost of pollution from gas cars, which are one of the primary uses of fossil fuels, which means that, in fact, gasoline vehicles receive much more subsidy than EVs do.
And yet, EVs still managed to grow substantially, despite these headwinds. EV sales have continued to grow, both in the US and globally, even as headlines incorrectly say otherwise. The republican party’s attempts to kill them were futile, and will continue to be.
It didn’t work, but it did delay progress
However, anti-EV actions from Mr. Trump and the republican party did manage to delay progress from where it could have been if America actually instituted smart industrial policy earlier.
What if, instead of the bumbling, idiotic nonsense we went through the last time Mr. Trump squatted in the White House, we could have had something more like President Biden’s EV policy, which created hundreds of thousands of jobs and attracted hundreds of billions of dollars of manufacturing investment?
Surely the American auto industry would be ahead of where it is now if those investments had had time to come online. But instead, republicans are currently trying to kill those jobs, which has already led to several manufacturing projects being cancelled this year, depriving Americans of the economic boost they need right now.
Meanwhile, there’s one place that this sort of stumbling isn’t happening: China.
China is taking advantage
China has spent more than a decade focusing on securing material supply, building refining capacity, developing their own battery technology, and encouraging local EV manufacturing startups.
This has paid off recently, as Chinese EVs have been rapidly scaling in production in recent years. It took a lot of the auto industry by surprise how rapidly Chinese companies have scaled, and how rapidly Chinese consumers have adopted them, after having an initially slow start.
But that adoption hasn’t just been local, it’s also global. Last year, China became the largest auto exporter in the world, taking a crown that Japan had held for decades. But the change was even more dramatic than that – as recently as 2020, China was the sixth-largest auto exporter in the world, just behind the US in 5th place.
China’s dramatic turn upward started in 2020, and now it’s in first place. Meanwhile, because of all the faffing about, the US remains exactly where it was in 2020 – still in fifth place. Well, sixth now, since China eclipsed us (and everyone else).
Tariffs won’t fix it
The reaction of the rest of the world’s automaking countries has been to put tariffs on Chinese autos, hoping to forestall the country’s dramatic rise to dominance. (Although, due to Mr. Trump’s idiotic flailing, Europe is already talking about removing these trade barriers with China)
But tariffs have been tried before, and they didn’t work. When Japan had a similarly meteoric rise to global prominence as an auto manufacturer in the 1970s and 80s, largely due to their adoption of new technology, processes, and different car styles which incumbents were ignoring, the US tried to stop it with tariffs.
All this did was make US manufacturers complacent, and Japan still managed to seize and maintain the crown of top auto exporter (occasionally trading places with Germany) from then until now.
Then as now, the true way to compete is to adapt to the changing automotive industry and take EVs seriously, rather than giving the auto industry excuses to be complacent. But instead, republicans aren’t doing that, and in fact are working to ensure the American auto industry doesn’t adapt, by actively killing the incentives that were leading to a boom in domestic manufacturing investment.
US auto industry jeopardized by republicans
Make no mistake about it: destroying EV incentives, and allowing companies to pollute more and innovate less, will not help the US auto industry catch up with a fast moving competitor.
As we at Electrek have said for years, you cannot catch up to a competitor that is both ahead of you and moving faster than you.
This applies to individual companies, which took their sweet time responding to the challenge from electric upstarts like Tesla, and have now lost market share to said upstarts and let a competitor establish itself in a big way (even though Tesla’s CEO is now trying desperately to harm his own company specifically, and the US EV industry as a whole, by being the largest funder of the party working to destroy said industry).
It also applies to nations, which could have spent the last decade doing what the Chinese auto industry has been doing, but instead non-Chinese automakers have been begging their governments for more time, even though it’s not the regulations that threaten them, it’s competition from a new and motivated rival that is moving faster and in a more determined manner towards the future.
The way that we get around this should be clear: take EVs seriously.
But that’s not what republicans are doing, and in doing so, they are signing the death warrant for an important US industry in the long term.
Another thing republicans are trying to kill is the the rooftop solar credit, which means you could have only until the end of this year to install rooftop solar on your home before the cost of doing so goes up by an average of ~$10,000. So if you want to go solar, get started now, because these things take time and the system needs to be active before you file for the credit.
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International equipment manufacturer Vermeer has unveiled a full-scale prototype of its Interlune excavator, a machine designed to ingest 100 metric tons of rocks and dirt per hour, extracting valuable helium as it makes its way across the surface … of the Moon.
Helium plays a critical role in the manufacturing of semiconductors, chips, optics, and all the other stuff that makes EVs, autonomy, the Internet, and the rest of twenty-first century life possible. The problem is that, despite being the second-most common element in the universe, helium is pretty rare on Earth – and we are rapidly running out. As such, there are intense economic and political pressures to find new and reliable sources of helium somewhere, anywhere else, and that demand has sparked a new modern space race focused on harvesting helium on the Moon and getting it back home.
To that end, companies like American lunar mining startup Interlune and the Iowa-based equipment experts at Vermeer are partnering on the development of suite of interplanetary equipment assets capable of digging up lunar materials like rocks and sand from up to three meters below the surface, extract helium-3 (a light, stable isotope of helium believed to exist in abundance on the Moon), then package it, contain it, and ship it back to Earth.
“When you’re operating equipment on the Moon, reliability and performance standards are at a new level,” says Rob Meyerson, Interlune CEO. “Vermeer has a legacy of innovation and excellence that started more than 75 years ago, which makes them the ideal partner for Interlune.”
Enter: Japan
America isn’t the only spacefaring nation eyeing a helium mine on the Moon. Japan announced similar plans back in 2023, with Japanese construction giant Komatsu announcing plans to develop a fully electric excavator capable of operating on the lunar surface.
The company showed a scaled prototype of the machine at the 2025 Consumer Electronics Show (CES) in Las Vegas (above), emphasizing the need to develop new ways to operate equipment assets in the extreme temperatures of extraplanetary environments beyond diesel or even hydrogen combustion.
On the airless surface of the moon, it would be impossible for an internal combustion engine to operate on the moon’s surface because there is no oxygen for combustion. Electrically powered machines seem the obvious solution with solar power generation supplying the electricity. But the answer is not that simple.
Temperature changes on the surface of the moon are extreme. They can soar to 110° C and plummet to -170° C. Developing electric construction machinery to perform in this environment is no easy task, but Komatsu is tackling issues one by one as they appear. Using thermal control and other electrification technologies, we are engineering solutions.
Despite Komatsu’s apparent head start, however, Vermeer seem to pulled ahead – not just in terms of machine development, but in terms of extraction potential as well.
“The high-rate excavation needed to harvest helium-3 from the Moon in large quantities has never been attempted before, let alone with high efficiency,” said Gary Lai, Interlune co-founder and CTO. “Vermeer’s response to such an ambitious assignment was to move fast. We’ve been very pleased with the results of the test program to date and look forward to the next phase of development.”
Interlune is funded by grants from the US Department of Energy and NASA TechFlights. In 2023, the company received a National Science Foundation (NSF) Small Business Innovation Research award to develop the technology to size and sort lunar regolith (read: dirt). Interlune has raised $18 million in funding so far, and is planning its first mission to the Moon before 2030.
Electrek’s Take
We’ve got space travel, weird mineral extraction from another planet that’s essential for our technology, and a rapid, unchecked proliferation of AI. All we need now is big worms, a whole bunch of hallucinogenic narcotics, and the will to smash up a bunch of data centers with baseball bats – then we’ll have a pretty decent Dune LARP going. Yee-ha!
SOURCE | IMAGES: Interlune.
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