Steel For Fuel N° 003 of 56 25 Apr 2023
Will the EV supply chain hold?
by Andy Lubershane, Partner and Head of Research, Energy Impact Partners
In this note
The question
Will the mineral and manufacturing supply chain behind electric vehicles keep up with the demand the energy transition places on it?
The answer
He will not say yes. The post opens and closes on crossed fingers, and the reason is that the binding risks sit above ground rather than below: permitting and community opposition, mine lead times of a decade or more, and a chain that runs through China at nearly every step. He treats the geology as sufficient and the politics as the open question.
03The argument
The stakes come first, because they set up why a hedged answer is still an alarming one. Electric vehicles are pivotal, he argues, precisely because there is no good substitute. Hydrogen was once the rival and remains the best fallback, but running electrolysis through a fuel cell wastes most of the energy compared with charging a battery directly, so a hydrogen-fuelled vehicle fleet would need roughly three times as much zero-carbon generation behind it. Hydrogen is also far behind on supply chain investment and infrastructure, and the major vehicle manufacturers are, in his phrase, pot-committed to batteries. A supply chain failure therefore does not reroute the transition; it stalls it, and the alternative is both worse and more than a decade away.
The optimistic half of the essay is a story about scale, and about substitution inside the battery. Lithium-ion has improved steadily even while the industry expanded by orders of magnitude, and cell costs collapsed as gigafactories arrived; his summary of that decade is never to bet against economies of scale. The same logic softens the mineral problem, because the frightening inputs turn out to be replaceable. Cathodes made from lithium, iron and phosphate are cheaper and easier to source than the nickel-manganese-cobalt blends, already standard in stationary storage and making headway in vehicles despite lower energy density, and he is increasingly convinced they can displace the older chemistry in many applications. That matters mostly because of cobalt, which he treats as the one genuinely existential input: the most geographically concentrated of the transition minerals, concentrated in a country with severe governance problems, and probably not abundant enough for mass-market global adoption even so. Sodium-ion, which could substitute for lithium itself, he flags as a watch item rather than a solution, noting that consensus puts its energy density too low for most vehicles.
Then the turn. None of this is where the risk actually lives. Reserve estimates suggest there is enough of everything in the crust except possibly cobalt, so the constraint is the speed at which material can be got out and processed. New mines often take a decade or more and, for nickel and copper, which he calls the extreme cases, have averaged considerably longer; recycling and reuse will help but cannot cover more than a modest share of inputs within the decade; and the obstacles that make new projects uneconomic are often environmental and procedural. That is also his explanation for China’s dominance, which he is careful to state as a capability rather than a conspiracy: China can build big things fast, including things that carry environmental risk, and the United States currently cannot. He is sympathetic to why, asking who would want to live beside a rare earth mine or a lithium evaporation pond, and he points to the Lithium Triangle as the pattern in miniature: very dilute brines, an extraction method that recovers less than half the lithium and provokes real conflict over land and water, siting stalled as a result, and new supply arriving instead from Australian hard rock, which he considers a less robust long-term option.
So the essay ends where it cannot resolve. Direct lithium extraction would remove the evaporation ponds and is being pursued from several directions; he calls that problem solvable but far from solved, which is roughly his verdict on the whole chain. The question he actually leaves the reader with is not about minerals at all but about whether US-China relations hold, and his answer to that is to describe what his firm is funding while everyone waits.
04What you need to know first
- Power-to-wheels efficiency
- How much of the energy from a primary source such as wind or solar ends up as motion in a vehicle. He gives electric motors above 90%, combustion engines 30-40% and hydrogen fuel cells 40-60%.
- NMC/A and LFP
- The two families of cathode, the positively charged side of a battery cell. The first blends nickel, manganese, cobalt and aluminium; the second uses lithium, iron and phosphate and avoids cobalt entirely.
- Above-ground risk
- His organizing idea: the danger is not that the mineral is missing from the earth but that permits, communities, capital and politics prevent it being extracted and processed on time.
- Direct lithium extraction
- A set of methods for pulling lithium out of underground brine without evaporation ponds, returning most of the brine to the aquifer.
05Details worth keeping
- The post belongs to a series he calls the Ten Biggest Questions in Energy and Climate Tech, and links to the rest at the end.
- He is enthusiastic about replacing small diesel engines specifically, on noise, local pollutants and operating cost rather than carbon, citing portable battery generators and electric autonomous commercial lawnmowers, all named as his firm’s investments.
- On grid storage he expects lithium to be displaced over time, since weight does not matter for stationary systems, but says its industrial scale makes it the cheapest option for now at durations of two to six hours.
- His own chemistry positions are given and then disclaimed: bullish on silicon anodes, sceptical of solid-state electrolytes, hopeful about sulfur cathodes, and explicit that readers should look elsewhere for battery chemistry advice.
- The text carries a bracketed update added after publication, announcing a June 2023 investment in a copper extraction company.
- A footnote flags phosphorus as a thing to watch if lithium-iron-phosphate wins, not because batteries would consume much of it but because it is a pressure point in fertilizer and food supply.
- Several figures carry the evidence for claims the prose only asserts, including the inflection in grid-scale storage, the geographic concentration of production, and the comparison of what China and the United States can build. The note cannot reproduce them.
06Claims worth citing
All figures as stated on 2023-04-25. Battery costs, cell manufacturing capacity and the status of sodium-ion move fastest.
- Hydrogen produced by electrolysis and run through a fuel cell delivers about 25% power-to-wheels efficiency against about 70% for direct electrification, so a hydrogen fleet would need nearly three times the zero-carbon generation. Lubershane
- About 1% of cars in the US are powered by lithium batteries. Lubershane
- Lawnmowers account for 5% of the worst criteria pollutants, emitted next to homes and schools. US Environmental Protection Agency, cited by Lubershane
- Since 2010, energy density and cycle life have improved by 25-50% while the global supply chain expanded roughly a thousandfold. Lubershane
- Tesla’s 2013 gigafactory announcement was for 50 GWh a year, about a hundred times any operating facility at the time; the world now has more than ten times that capacity, and 1 GWh is enough for about 14,000 vehicles. Lubershane
- A 70 kWh battery pack would have cost about $70,000 in 2010 and about $10,000 by 2020, while weighing less, taking less space and lasting longer. Lubershane
- Lithium-iron-phosphate cells are about 25-30% less energy-dense than nickel-manganese-cobalt blends at the cell level. Lubershane
- At roughly 150 tons of cobalt per GWh, known reserves of 8.3m tons would supply about 800m vehicle batteries, which he says falls far short of full global electrification even if cobalt per battery were halved. Lubershane, in a footnote
- New mines often take a decade or more from discovery to production; nickel and copper mines have averaged more than 15 years over the past decade, and the world’s last two major copper mines took about 30 years each. Lubershane
- Recycling and reuse together could supply roughly 10-15% of critical mineral inputs to new batteries by 2030. International Energy Agency 2021 report, cited by Lubershane
- China produces more than 90% of intermediate battery materials, the electrode powders and electrolyte precursors without which new Western cell plants would sit idle. Lubershane, crediting a colleague’s chart
- Brines in the Lithium Triangle contain less than 0.1% lithium, and the conventional evaporation method typically recovers less than half of what is there. Lubershane
- The current recycling rate for rare earth elements is less than 1%. Lubershane
07Where it’s contested
There is no second voice. The disagreement in this post is with its own question: the headline answer is an admitted hedge, and most of the forecasts inside it are labelled as guesses.
- The answer is a shrug, deliberately. He calls crossed fingers the best answer he can muster, and frames the whole piece as a current hypothesis.
- The battery improvement forecast is marked as a personal guess. Another 25-50% on density and fast charging by around 2030 comes from reading market signals and talking to early-stage companies, and he tells readers to seek chemistry advice elsewhere.
- He is mid-revision on cathodes. He says he is becoming increasingly convinced that the cobalt-free chemistry can displace the older blends in many and perhaps most applications, which is a position forming rather than a finding.
- Sodium-ion runs against the consensus he reports. He passes on the market view that its density is too low for most vehicles and then argues it could be one of the decade’s biggest surprises anyway.
- The central premise rests on reserve estimates taken at face value. That the constraint is above ground rather than below follows from geological survey figures he cites but does not interrogate, and the cobalt exception is worked out in a footnote.
- The question the essay raises last is the one it does not answer. Whether the supply chain holds is converted into whether US-China relations hold, and the post goes no further than asking.
- He has a stake in the remedies. The solutions section is a list of his firm’s investments, disclosed as such, and the claim that one of them could underpin robust domestic supply chains is the firm’s belief about its own portfolio company rather than a demonstrated result.