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Memo 

To: Docket EPA-HQ-OAR-2010-0799

From: Joseph McDonald 

CC: Ed Nam, U.S. EPA-OTAQ-ASD 

Date: Tuesday, November 29, 2011 

Re: Santini, Gallagher and Nelson EVS-25 Paper 

A hard copy of the following citation: 

Santini, D.J., Gallagher, K.G., and Nelson, P.A. “Modeling of Manufacturing Costs of Lithium-Ion 

Batteries for HEVs, PHEVs, and EVs,” Paper presented at the 25th World Battery, Hybrid and Fuel Cell 

Electric Vehicle Symposium and Exposition, EVS-25, Shenzhen, China, November 5-9, 2010 

(www.evs25.org). 

is available within EPA’s Docket Center. 

This document has been copyrighted and is not available in the electronic docket. Parties that wish to 

view a hard copy of this document can do so at the at the EPA Docket Center: Air and Radiation 

Docket and Information Center, EPA/DC, EPA West, Room 3334, 1301 Constitution Ave., NW, 

Washington DC. The Public Reading Room is open from 8:30 a.m. to 4:30 p.m., Monday through 

Friday, excluding legal holidays. The telephone number for the Public Reading Room is (202) 566-

1744, and the telephone number for the Air Docket is (202) 566-1742. 

Document Abstract: 

In this study, we present a refined model for calculating the costs of lithium-ion batteries supporting electric drive in 

light duty passenger vehicles (LDVs). The model calculates the annual materials requirements from design criteria 

for the battery pack including power, capacity, number of cells, and cell chemistry parameters. The costs of capital 

equipment, plant area and labor for each step in the manufacturing process were estimated for a baseline plant. 

These costs are adjusted for each battery pack studied by comparing the processing rate pertinent for each step 

(area to be coated, number of cells to be tested, etc.) with that of the baseline process and applying correction 

factors. We applied the cost modeling method to batteries with five lithium-ion cell chemistries; for three significantly 

different levels of power, for several levels of energy storage, within four major electric drive options (HEV, PHEV, 

E-REV, and EV) simulated to power an advanced “low load” mid-size U.S. passenger car body. E-REVs and the 

EV battery packs require significant 10 second peak power pulses from 148-158 kW to achieve 32 to 160 km of 

reliable all electric operation. For the PHEVs a maximum of 62 kW is estimated to be required, and achievement of 

only limited all electric operations capability is accepted. Two HEV power levels are examined: 25 kW peak for 2 

seconds; 52 kW peak for 10 seconds. The cost, volume, and mass implications of the power levels modeled are 

analyzed and discussed. Although many factors beyond the scope of the model will be important in selecting 

among the chemistries examined, there are some significant differences in estimated costs. Two of the five 

chemistries are found to have attributes making them relatively unsuitable for high power-to-energy ratio battery 

packs for HEVs. However, these chemistries do appear competitive with the other three for plug-in electric drive 

options. Among the chemistries examined, the lithium manganese spinel / graphite chemistry is consistently 

estimated to be the least expensive and often the smallest in weight and volume.