Decarbonizing EV battery plants: 6 ways EVBPs can reduce their carbon footprint

The automotive industry is a significant contributor to global greenhouse gas (GHG) emissions. While electric vehicles (EVs) are increasingly adopted to reduce the carbon footprint of road transportation, the manufacturing processes of EV battery plants (EVBPs) must also be addressed to achieve true sustainability.

EV battery manufacturing is highly energy-intensive, raising concerns about the overall CO2 emissions from production to disposal. By decarbonizing their processes, EVBPs can not only reduce their own emissions but also position themselves as environmentally friendly options for original equipment manufacturers (OEMs) and EV buyers. Many automotive OEMs have made bold pledges to improve sustainability, including goals to achieve carbon reduction across their entire fleets.

Six Actions for EV Battery Plants to Decarbonize:

1. Electrify Industrial Processes: EV battery production is responsible for 40-60% of an EV’s total production emissions. EVBPs can significantly reduce their carbon footprint by electrifying their processes and using low-carbon electricity. For instance, transitioning from gas to electric in the coating and drying processes, as well as in dry and clean rooms, can enhance energy performance by more than 10%. This shift not only reduces emissions but also improves the overall efficiency of the production process.

2. Increase Energy Efficiency: Improving energy efficiency is one of the most cost-effective ways for EVBPs to reduce GHG emissions. It benefits both the environment and the bottom line, as using less energy translates to cost savings. Energy efficiency can be enhanced through the use of software and analytics that monitor energy consumption. For example, EcoStruxure Power Monitoring, an ISO 50001 compliant software, can accurately assess and determine the energy, water, and other utilities consumed by different processes and areas within the EVBP. This information can be used to optimize operational and energy efficiencies, pinpoint energy-inefficient systems, identify areas for maintenance, and provide trends and reports on energy efficiency.

Additionally, by utilizing direct current (DC) solutions directly in the formation process, manufacturers can bypass the need to convert alternating current (AC) to DC, which is typically required several times in the process. This change can lead to improved energy efficiency and reduced power losses associated with conversion. DC Systems by Schneider Electric offer a comprehensive solution that leverages technology and the Industrial Internet of Things (IIoT) to forecast a plant’s total energy usage and utilize on-site distributed energy resources like battery energy storage systems. This provides the flexibility to aid the grid and utilities by curbing consumption during peak periods, contributing to sustainable energy practices.

3. Procure Renewable Energy: EVBPs can enhance their sustainability by using green, renewable-based power instead of fossil fuels. There are three main ways to procure renewable energy:

• Energy Attribution Certificates (EACs): These certificates are tradeable and guarantee that one megawatt-hour (MWh) of electricity has been produced from renewable energy sources. By purchasing EACs, EVBPs can support carbon emissions reduction claims.
• On-site Generation: EVBPs can generate and store green power on-site using technologies like solar panels and microgrids. This approach not only reduces reliance on fossil fuels but also provides energy security and resilience.
• Off-site Generation: EVBPs can also purchase green power generated off-site through power purchase agreements (PPAs), which can be virtual, direct, or retail. PPAs allow EVBPs to secure long-term renewable energy at stable prices, contributing to their sustainability goals.

4. Engage Suppliers to Reduce Scope 3 Emissions: Reducing Scope 3 emissions, which are outside the direct control of EVBPs, is crucial for improving sustainability. The majority of a business’s carbon emissions come from Scope 3, which includes emissions from the supply chain. A supplier engagement program can help decarbonize Scope 3 emissions by leveraging platforms like CONNECT, an Industrial Intelligent Platform that models and measures resource use and supports suppliers’ decarbonization initiatives. This program can be tailored to suppliers’ varying characteristics, such as maturity and CO2 intensity, and can be used to educate, enable, and engage suppliers.

Moreover, CONNECT provides EVBPs with the essential tools needed to meet the digital battery passport’s requirements. It promotes transparency, interoperability, and collaboration among all value chain stakeholders, supporting the goal of a circular economy. Serving as a unified point of reference, it connects diverse ecosystems and ensures a single, reliable source of information.

5. Reduce Waste and Improve Traceability: Approximately 20% of scrap in an average gigafactory comes from the mixing to pack assembly stages. This waste can be reduced by improving production and process traceability. By leveraging battery traceability and modeling production and process steps through a digital platform, EV battery manufacturers can proactively understand and address deviations at early stages using machine learning. This approach not only aligns with lean principles by mitigating the eight main wastes but also lowers energy consumption per kilowatt-hour of each cell produced, leading to a more sustainable production process.

6. Use SF6-Free Switchgear and Asset Management: Switching from traditional SF6-insulated switchgear to SF6-free alternatives, such as Schneider Electric’s SM AirSeT, can contribute to Scope 1 CO2 reduction by eliminating the direct greenhouse gas emissions associated with SF6. By adopting SF6-free solutions, EV battery manufacturers can significantly reduce their direct emissions, thereby positively impacting their Scope 1 CO2 footprint. This transition aligns with sustainability goals and supports efforts to mitigate climate change.

In addition, asset management that leverages predictive, condition-based maintenance (CBM) can reduce an EVBP’s carbon footprint by optimizing equipment health and EV battery performance. This proactive maintenance strategy can extend the lifespan of equipment, delaying the environmental impact of equipment replacement, which includes energy use in production and transportation, raw mineral extraction, and disposal of obsolete equipment.

CBM uses connected technology and data analytics to manage equipment health by predicting and planning maintenance needs based on data about assets and processes. EcoCare by Schneider Electric utilizes cutting-edge technology like Asset Advisor and Power Advisor, supported by the expertise of subject matter experts, to proactively extend the remaining useful life of assets.

Visit our website for more details on how EVBPs can reduce their carbon footprint.

Tags: Decarbonization, Energy Efficiency, EV Battery, EV Battery Manufacturing, EV Battery Plant