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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Xiaomi has confirmed receiving over 200,000 real orders for its Tesla killer, the YU7, in just three minutes. We are referring to actual orders, with a soon-to-be non-refundable deposit.
Today, Xiaomi launched its second vehicle, the YU7, coming just four years after establishing its EV division and less than a year after introducing its first car, the SU7.
For years, we laughed at the media calling every new EV a ‘Tesla killer’, but over the last few weeks, we have reported how the YU7 might be the first real one.
At the launch event, CEO Lei Jun was not shy about making comparisons to Tesla.
While the CEO praised the automaker for its leading efficiency and ADAS system, Lei Jun released a series of slides that favorably compared the YU7 to the Model Y.
It started with a comparison of the entire dimensions of both vehicles (image translated via Google):
Xiaomi’s CEO then claimed that the new YU7 had a significantly quite cabin with much less road noises than Tesla’s best-selling SUV (image translated via Google):
In my first drive of the YU7, I did note that the cabin was ultra quiet and demonstrated it briefly in my Youtube video about the new electric SUV:
The double-panned acoustic glass all around helps with that, but the vehicle’s suspension is also optimized for noise, as well as active noise cancellation throughout the car.
Xiaomi also claimed that the vehicle, especially its electro-shading sunroof, was able to keep the cabin much cooler in extreme heat than Tesla’s Model Y (image translated via Google):
Lei Jun even shared a tweet that he posted about challenging Tesla Model Y’s best-selling crown and then truly went on the attack with pricing.
Ahead of today’s event Xiaomi had already shared a lot of information about the YU7, but pricing was the last significant piece of the puzzle.
The CEO decided to release with a direct comparison of each variant to Tesla’s own Model Y variant, and it was pretty brutal.
The base YU7 starts at just 253,500 RMB (equivalent to $35,300 USD) – 10,000 RMB less than Tesla, and it offers more than 200 extra km in range (image translated via Google):
As for the YU7 Pro, it starts at 279,900 RMB (equivalent to $39,000 USD), more than 30,000 RMB less than Tesla’s Model Y Long Range and it also compares quite favorably on the main features, including range (image translated via Google):
Finally, the YU7 Max was announced at 329,900 RMB (equivalent to $46,000 USD), 25,000 RMB less than Model Y Performance, and the specs are not even close:
With these incredibly favorable comparisons to Tesla’s best-selling SUV, it’s not surprising that Xiaomi has received record demand for the YU7.
It reported having received over 200,000 orders for the new electric vehicle within 3 minutes of opening orders at 10PM local time on Thursday.
It’s also important to note that these orders represent a genuine show of interest. This is not a Cybertruck situation where Tesla claimed to have over 1 million reservations, but ended up only selling about 50,000 units.
People ordering the vehicle need to place a 5,000 RMB (~700$) deposit, which only remains refundable for a few days before the order becomes locked in.
Xiaomi has already started production of the YU7 and made units available for delivery (with configurations limited to those pre-arranged by their designers) for almost immediate delivery.
Electrek’s Take
It’s hard to overestimate just how much this shook up the industry. At an average sale price of $40,000, that’s about $8 billion in sales that Xiaomi booked in 3 minutes.
I would expect the tally to increase past 400,000 in the coming days, and it will likely lock up a significant portion of potential buyers in the segment, particularly Model Y, for an extended period.
Tesla was already experiencing problems in China and had to offer record incentives to maintain its sales, but it will now face even greater challenges in the second half of the year.
I expect that Tesla will quickly launch its lower priced stripped down Model Y to try to help demand following this beating.
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BYD says there’s no slowdown, despite the rumors. After several sources claimed that BYD was cutting EV production in China due to slowing sales, the company is pushing back, saying output is stable and sales are still growing.
Why is BYD cutting EV production in China?
With nearly 382,476 new energy vehicles (NEVs) sold globally in May, BYD is coming off its best sales month of 2025.
Like most carmakers in China, BYD reports monthly NEV sales, which include fully electric vehicles (EVs) and plug-in hybrids (PHEVs).
BYD’s sales are up 39% through the first five months of the year, with over 1.76 million NEVs sold worldwide. Not including its commercial vehicles, BYD’s passenger vehicle sales are up 37% through May, with over 1.73 million units sold.
Its battery-electric vehicles (EVs) are leading the growth, with sales up 40% through the first five months of 2025 compared to the same period last year.
After a few sources claimed the growth was not enough and the company was already cutting EV production over slowing sales, BYD is shutting down the rumors.
Two people close to the matter told Reuters on Wednesday that BYD had slowed output at several factories in China. They added that the company was also reportedly delaying plans to add lines to expand output.
The sources claimed that BYD has cut night shifts and reduced capacity at some plants by at least a third as it faces rising inventory. One of them reported that at least four BYD plants are now operating at a slower pace.
On Thursday, a seperate source, close to BYD, told CnEVPost that the rumors are not true. According to the person familiar with the matter, BYD’s production remains stable and sales are still growing steadily. The source added that dealer inventory is at reasonable level.
If true, the claims could have been pretty significant, given BYD’s aggressive price cuts last month. On May 23, BYD slashed prices by up to 34% on 22 of its vehicles.
BYD still expects to sell around 5.5 million vehicles this year, a nearly 30% increase from 2024. Last year, BYD sold over 4.72 million NEVs, up 41% from 2023. However, its annual growth rate has slowed over the past few years.
According to data from CnEVPost, BYD’s annual sales growth rate has declined from 218% in 2021 to 208% in 2022 and 62% in 2023.
The Reuters report cited a survey from the China Automotive Dealer Association last month found that BYD dealers held one of the highest inventory levels, with an average of 3.21 months. In comparison, the industry-wide average was 1.38 months.
Despite this, BYD is still gaining market share in China. The source told CnEVPost that BYD’s share of the auto market has risen from 15% to 17% in just the past few months
Electrek’s Take
With an intensifying EV price war and a wave of low-cost domestic cars flooding the market, Chinese automakers, including BYD, are now looking overseas to drive growth.
BYD is coming off its sixth consecutive month with record overseas sales in May, having sold over 89,000 NEVs outside of China.
After it topped Tesla in monthly vehicle registrations in Europe and the UK this year, BYD launched its most affordable EV earlier this month. The Dolphin Surf is the European version of its top-selling Seagull EV, which can be bought for under $8,000 in China right now.
BYD’s Dolphin Surf arrives as one of the most affordable vehicles in the UK, starting at just £18,650 (about $25,000).
During the launch event, BYD’s special advisor for Europe, Alfredo Altavilla, called (via Autocar) the Dolphin Surf “the missing piece in the A/B-segment.”
According to Altavilla, BYD is launching vehicles in Europe at a faster rate than any other carmaker. “I have zero problem in saying I don’t think there has ever been such a product offensive done in Europe as the one BYD is doing,” he said during the event.
BYD’s sales are expected to double in Europe this year to around 186,000 units. By 2029, S&P Global Mobility forecasts BYD’s sales could reach around 400,000 in Europe. Between its new plants in Hungary and Turkey, BYD is expected to have a combined annual production capacity of over 500,000 units.
And Europe is just one global market. BYD is already a leading EV brand in overseas markets like Brazil, Thailand, Australia, and several other key markets.
Even if the sources’ claims that BYD is cutting production in China were true, the world’s leading EV maker is still expected to see significant growth overseas over the next few years.
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Airloom Energy just broke ground on a rectangular wind turbine pilot site near Rock River, Wyoming, and it has the potential to change how wind power gets built in the US.
Backed by Bill Gates’ Breakthrough Energy Ventures, Airloom is developing a new kind of wind turbine that promises to be cheaper, faster to install, and more efficient than today’s towering three-blade giants. The Wyoming site will host the company’s first utility-scale turbine as part of a plan to prove the tech works in the real world.
This comes at a time when the grid could use some more innovation. The North American Electric Reliability Corporation (NERC) says half the US could face energy shortfalls by 2035. And with AI and data centers driving up demand, Gartner warns that 40% of facilities worldwide will be constrained by access to sufficient power by 2027.
“Current energy technologies can’t meet the growing complexity and demand of the next decade,” said Neal Rickner, Airloom’s CEO. “We need more flexible systems that can be built fast and at scale. That’s the only way we’ll get to real energy security and independence.”
Airloom’s turbines are compact and modular. Instead of sweeping a circular area like traditional turbines, the turbines in the pilot sweep a rectangular area – a design that lets them capture more wind in less space. That makes them a better fit for areas with limited land or strict height limits, like airports or military bases.
They’re also built with small, mass-produced parts made in the US, so they’re cheaper to ship and easier to install. While traditional wind projects can take up to five years to build, Airloom says its turbines can be up and running in under a year.
The Wyoming pilot site is meant to prove the turbines’ performance, validate the cost savings, and build out maintenance and deployment strategies ahead of commercial projects starting in 2027. Airloom is also exploring other use cases like defense, disaster relief, and offshore wind.
The company raised $7.5 million in seed funding last October, with support from Breakthrough Energy Ventures, Lowercarbon Capital, Crosscut Ventures, and others. It also received $5 million in matching funds from the State of Wyoming and a $1.25 million contract from the Department of Defense.
Paul Judge, former head of product management at GE Onshore Wind and now an advisor to Airloom, called the pilot a big moment: “This pilot is more than a test site; it’s the beginning of a fundamentally new approach to resilient renewable energy generation: wind energy that’s faster to deploy, land-efficient, and built for the energy challenges ahead.”
Read more: New DOE report finds 90% of wind turbine materials are recyclable
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