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Lithium Iron Phosphate Battery Cell Chemistry is Taking Over the Automotive Market: What it Means for Auto Educators

by  Nick Goodnight     Mar 27, 2023
1280px-Lithium_Iron_Phosphate_LiFePO4_Cells_700Ah_in_Parallel_and_Series_and_Busbar_-_1

Precious metals have always been one of the major setbacks to mass adoption of electric vehicles (EV). From Cobalt to Manganese and Nickel, these minerals make up the majority of cost and wear within a lithium battery cell.

To help with minimizing the effect of these materials on the cost of an EV, the transition to lithium iron phosphate (LFP or LiFePO4) battery technology is taking the EV space by storm.

LFP batteries are lighter by approximately 50% on conventional lithium cobalt technology and up to 70% lighter than lead acid technology. They offer better efficiency, but do not have an increased energy density, though they can be a better choice for some applications. One of the benefits to using a LFP is the ability to charge it up to 100% without cell damage or potential for pack failure.

LFP batteries are less expensive than other types of lithium-ion batteries due to their simpler manufacturing process, making them an attractive option for automakers. The biggest cost within a conventional EV battery pack is the cost of the raw material within the pack. Nickel, Manganese and Cobalt are all rare earth minerals which are not easily available everywhere.

Changing the materials in the battery pack can decrease the cost and it can be sourced closer to the manufacturer. Tweaking the chemistry within the pack is how the range can increase and the cost can further decrease. LFP’s have a longer cycle life compared to other lithium-ion batteries (4,000 to 5,000 cycles), meaning they can be charged and discharged more times before reaching the end of their useful life and can be fast charged with minimal effect on the condition of the battery cells.

Read on to learn about how LFP battery technology is impacting the industry, and how you can incorporate this information in your courses and curricula.

Cell Design

Increasingly one of the EV short comings is the potential for fire after a collision or thermal runaway event that cannot be controlled. LFP batteries utilize lithium ferrous phosphate (LiFePO4) as the cathode material and graphite carbon electrode as the anode in the cell. LiFePO4 batteries have a nominal battery cell voltage of 3.2v per cell, where a conventional NCA or NMC battery cell has a nominal cell voltage of 3.7 v per cell. This is primarily because the lack of Nickel content which will not allow the cell to be as power dense as the heavily Nickel chemistries of the other form factors. 

The chemistry of this battery cell allows for a very high temperature (270 degrees Celsius) before thermal runaway occurs. The higher the temperature the cell can resist, the less of the possibility a fire will start within the pack.

The energy density is 15-20% lower than a Nickel comprised battery cell, which can be made up by utilizing more cells or designing the pack for a particular purpose. With this lower power density proper cell application must be thought out so the driver of the vehicle will not have range anxiety and have a great experience.

One of the major issues with mass EV adoption is the comparison to a conventional ICE powered vehicle and how the person has been conditioned to do minimal pre planning because a fuel station is usually within easy reach and fill up times are less than 10 minutes. To help with minimizing the range anxiety most EV’s have a network subscription to allow the driver to access the OEM’s charging network throughout the US and easily direct the driver to those locations while helping them plan out their trip in real time.

Environmental and Manufacturing Factors

Conventional NCA, NMC chemistry are more susceptible to low temperatures which will reduce the capacity of the cells and range can be compromised.

Manufacturers are moving towards utilizing LFP chemistry battery types for the lower cost of production, consistent energy density, higher tolerance for being fully charged and can tolerate fast charging times.

Ford Motor company is moving towards this type of chemistry in their Mustang Mach E and will introduce them in the Ford Lightning as an option next year. Along with Ford; Tesla and Stellantis all have released plans to utilize LFP batteries throughout their EV platforms. This change will decrease the cost of lithium battery cells along with increasing the longevity of the battery packs to help decrease the cost of EV production.  

With the increased use of this type of technology, battery cell manufactures like CATL, have been cutting prices of cells, like they did at the beginning of 2023. A 15% cost reduction of cell manufacturing has helped mass adoption of this type of chemistry and it will continue to grow.

Mass adoption of any technology can only be accomplished as that technology implementation price becomes attainable by the masses. With LFP prices coming down to around $131 dollars per kilowatt hour or less, their usage will continue to accelerate.

Another major issue with mass LFP adoptions is the majority of the materials needed for LFP cell production is located in China. With China cornering the market of the transition to full EV operation, the development of different sources of materials must be accomplished to flatten the supply chain. The constraints of one major source and global demand outstripping supply. Energy research and consultancy firm Wood Mackenzie predict global lithium-ion capacity will rise five-fold by 2030. Within that time frame LFP will surpass NCM technology cells by 2028.

LFP battery technology is but just another step on the path to a carbon neutral transportation industry. Creating an automobile with characteristics of an ICE vehicle, while getting the buy-in needed from the driving public, is key to pushing battery technology forward. Without these incremental steps in battery technology this reality could never be realized.

The automotive technician of tomorrow will have to know their way around these types of technologies and how they apply to the customers lives, and there is a very steep learning curve. When coupled with a dwindling workforce within the trade, we, as instructors and automotive leaders, need to find different ways to inspire a new generation by showing them how the transition is gaining steam and will “keep the lights on” in the repair facility.

To learn more about LFP and other battery technologies check out Light Duty and Electric Vehicles, First Edition from CDX Learning Systems.

Read More:

About the author:

Nicholas Goodnight, PhD is an ASE Master Certified Automotive and Truck Technician and an Instructor at Ivy Tech Community College. With nearly 20 years of industry experience, he brings his passion and expertise to teaching college students the workplace skills they need on the job. For the last several years, Dr. Goodnight has taught in his local community of Fort Wayne and enjoys helping others succeed in their desire to become automotive technicians.

Photo: Wikimedia Commons

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Lithium Iron Phosphate Battery Cell Chemistry is Taking Over the Automotive Market: What it Means for Auto Educators

by  Nick Goodnight     Mar 27, 2023
1280px-Lithium_Iron_Phosphate_LiFePO4_Cells_700Ah_in_Parallel_and_Series_and_Busbar_-_1

Precious metals have always been one of the major setbacks to mass adoption of electric vehicles (EV). From Cobalt to Manganese and Nickel, these minerals make up the majority of cost and wear within a lithium battery cell.

To help with minimizing the effect of these materials on the cost of an EV, the transition to lithium iron phosphate (LFP or LiFePO4) battery technology is taking the EV space by storm.

LFP batteries are lighter by approximately 50% on conventional lithium cobalt technology and up to 70% lighter than lead acid technology. They offer better efficiency, but do not have an increased energy density, though they can be a better choice for some applications. One of the benefits to using a LFP is the ability to charge it up to 100% without cell damage or potential for pack failure.

LFP batteries are less expensive than other types of lithium-ion batteries due to their simpler manufacturing process, making them an attractive option for automakers. The biggest cost within a conventional EV battery pack is the cost of the raw material within the pack. Nickel, Manganese and Cobalt are all rare earth minerals which are not easily available everywhere.

Changing the materials in the battery pack can decrease the cost and it can be sourced closer to the manufacturer. Tweaking the chemistry within the pack is how the range can increase and the cost can further decrease. LFP’s have a longer cycle life compared to other lithium-ion batteries (4,000 to 5,000 cycles), meaning they can be charged and discharged more times before reaching the end of their useful life and can be fast charged with minimal effect on the condition of the battery cells.

Read on to learn about how LFP battery technology is impacting the industry, and how you can incorporate this information in your courses and curricula.

Cell Design

Increasingly one of the EV short comings is the potential for fire after a collision or thermal runaway event that cannot be controlled. LFP batteries utilize lithium ferrous phosphate (LiFePO4) as the cathode material and graphite carbon electrode as the anode in the cell. LiFePO4 batteries have a nominal battery cell voltage of 3.2v per cell, where a conventional NCA or NMC battery cell has a nominal cell voltage of 3.7 v per cell. This is primarily because the lack of Nickel content which will not allow the cell to be as power dense as the heavily Nickel chemistries of the other form factors. 

The chemistry of this battery cell allows for a very high temperature (270 degrees Celsius) before thermal runaway occurs. The higher the temperature the cell can resist, the less of the possibility a fire will start within the pack.

The energy density is 15-20% lower than a Nickel comprised battery cell, which can be made up by utilizing more cells or designing the pack for a particular purpose. With this lower power density proper cell application must be thought out so the driver of the vehicle will not have range anxiety and have a great experience.

One of the major issues with mass EV adoption is the comparison to a conventional ICE powered vehicle and how the person has been conditioned to do minimal pre planning because a fuel station is usually within easy reach and fill up times are less than 10 minutes. To help with minimizing the range anxiety most EV’s have a network subscription to allow the driver to access the OEM’s charging network throughout the US and easily direct the driver to those locations while helping them plan out their trip in real time.

Environmental and Manufacturing Factors

Conventional NCA, NMC chemistry are more susceptible to low temperatures which will reduce the capacity of the cells and range can be compromised.

Manufacturers are moving towards utilizing LFP chemistry battery types for the lower cost of production, consistent energy density, higher tolerance for being fully charged and can tolerate fast charging times.

Ford Motor company is moving towards this type of chemistry in their Mustang Mach E and will introduce them in the Ford Lightning as an option next year. Along with Ford; Tesla and Stellantis all have released plans to utilize LFP batteries throughout their EV platforms. This change will decrease the cost of lithium battery cells along with increasing the longevity of the battery packs to help decrease the cost of EV production.  

With the increased use of this type of technology, battery cell manufactures like CATL, have been cutting prices of cells, like they did at the beginning of 2023. A 15% cost reduction of cell manufacturing has helped mass adoption of this type of chemistry and it will continue to grow.

Mass adoption of any technology can only be accomplished as that technology implementation price becomes attainable by the masses. With LFP prices coming down to around $131 dollars per kilowatt hour or less, their usage will continue to accelerate.

Another major issue with mass LFP adoptions is the majority of the materials needed for LFP cell production is located in China. With China cornering the market of the transition to full EV operation, the development of different sources of materials must be accomplished to flatten the supply chain. The constraints of one major source and global demand outstripping supply. Energy research and consultancy firm Wood Mackenzie predict global lithium-ion capacity will rise five-fold by 2030. Within that time frame LFP will surpass NCM technology cells by 2028.

LFP battery technology is but just another step on the path to a carbon neutral transportation industry. Creating an automobile with characteristics of an ICE vehicle, while getting the buy-in needed from the driving public, is key to pushing battery technology forward. Without these incremental steps in battery technology this reality could never be realized.

The automotive technician of tomorrow will have to know their way around these types of technologies and how they apply to the customers lives, and there is a very steep learning curve. When coupled with a dwindling workforce within the trade, we, as instructors and automotive leaders, need to find different ways to inspire a new generation by showing them how the transition is gaining steam and will “keep the lights on” in the repair facility.

To learn more about LFP and other battery technologies check out Light Duty and Electric Vehicles, First Edition from CDX Learning Systems.

Read More:

About the author:

Nicholas Goodnight, PhD is an ASE Master Certified Automotive and Truck Technician and an Instructor at Ivy Tech Community College. With nearly 20 years of industry experience, he brings his passion and expertise to teaching college students the workplace skills they need on the job. For the last several years, Dr. Goodnight has taught in his local community of Fort Wayne and enjoys helping others succeed in their desire to become automotive technicians.

Photo: Wikimedia Commons

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