1 

# Memo

To: 

### Docket EPA-HQ-OAR-20 10-0799 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., Gall agher, K.G., and Nelson, P.A. “Modeling of Manufacturi ng 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 We st, 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 t he 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 tobe tested, etc.) with t hat of the baseline proce ss and applying correction factors. We applied the cost modeling met hod to batteries with five lithium-ion ce ll chemistries; for three significantly different levels of power, for several levels of energy st orage, within four major electr ic drive options (HEV, PHEV, E-REV, and EV) simulated to power an advanced “low l oad” mid-size U.S. passenger car body. E-REVs and the EV battery packs require significant 10 second peak powe r 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 c apability 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 attributesmaking them relatively unsuitable for high power-to-energy ratio battery packs for HEVs. However, these chemistr ies do appear competitive with the other three for plug-in electric drive options. Among the chemistries exami ned, the lithium manganese spinel / gr aphite chemistry is consistently estimated to be the least expensive and o ften the smallest in weight and volume.