Battery manufacturers are voicing the need for developing a robust cell manufacturing ecosystem, new cell chemistries, and technologies to accelerate EV adoption in India.
The rising adoption of EVs, increasing renewable energy installations, and the need for energy storage solutions have significantly contributed to the creation of a vast market for batteries in India. According to a study, the EV battery demand in India is expected to reach 15 GWh by 2025 and 60 GWh by 2030.
However, meeting this demand will be no less than a challenge, given India is largely dependent on foreign countries such as China for raw materials and EV components. With the growing demand for EVs in the country, it is the need of the hour to look into domestic manufacturing of batteries including li-ion and other chemistries.
If we closely look, in EVs, the battery serves as the most significant and costly component, accounting for nearly 40 per cent of the price of the vehicle. “This is primarily because India imports cells from China and the expenditure with respect to their logistics is high. In the long term, if China further increases the price of cells or if the country faces an issue with respect to its logistics, there is not much we can do to combat the situation then,” said Vikas Aggarwal, MD, iPower Batteries.
However, “If we aim to achieve quicker EV adoption, this dependence needs to be eliminated, and India needs to manufacture cells indigenously,” he added.
Agreeing with Aggarwal’s point of view, Pankaj Sharma, Co-Founder and Director at Log9 Materials, too emphasised on establishing indigenous supply chain within the EV sector. He says, “Localisation of EV supply chain will reduce our dependency on the neighbouring countries and take us closer towards our ambition of energy independence. It will also eventually lower the costs of EVs, thus boosting mass adoption of electric vehicles across all segments (2Ws, 3Ws, 4Ws).”
Sharma also highlighted the impact of domestic manufacturing on economic development. According to him, “reduced dependency on imports will drastically lower trade deficits, thereby improving the country’s economy. It will also reduce geopolitical tension, minimise supply chain disruptions and improve trade agreements.”
While developing a robust supply chain ecosystem is the need of the hour for EVs in India, battery manufacturers, on the other hand, highlighted the requisites and efforts they are making to strengthen domestic cell manufacturing.
Battery Recycling
As India’s battery market continues to grow, the scope for battery recycling is expected to expand significantly. By embracing battery recycling and investing in infrastructure, technology, and public awareness, we can effectively manage battery waste, reduce pollution, and recover valuable resources.
In India, several companies are actively engaged in exploring the second life of lithium batteries. “The recycled lithium batteries are anticipated to find utility in stand-alone energy storage solutions or will be used in EVs with limited range, especially in Tier-2 and Tier-3 cities and towns where price is a significant constraint in the adoption of EVs,” claims Aggarwal.
Improving Energy Density of Batteries
Improving the energy density of electric vehicles (EVs) in India is crucial for enhancing their range and performance.
Log9 Materials is moving towards advanced Titanate-based anode technologies with 2x charge capacity which would a provide better rate and higher energy density than the LTO. Shedding more details about this technology, Sharma informed “The team is working on LFP cell chemistry with cooling management systems that will support fast charging. Log9 is further working on materials that will help improve the energy density with no-cobalt chemistry, thus increasing the average cell voltage of system anodes. We have developed a product strategy that focuses on materials study to improve the energy density with no-cobalt concepts that minimises the use of critical raw materials.”
In terms of improving energy density, iPower Batteries has launched LMFP batteries. “These batteries offer a high energy density comparable to NMC batteries while maintaining the safety characteristics of LFP batteries,” notifies Aggarwal.
Innovating New Cell Chemistries
In EVs, advanced cell chemistries serve as the most critical component. While Lithium-ion batteries are the most preferred choice for EVs, Lithium Nickel Manganese Oxide (NMC) is the most predominant cathode chemistry. However, according to experts, Lithium Iron Phosphate (LFP) will gain prominence in the future, owing to its higher thermal stability and lower production cost.
Though several other chemistries are in the development process, an Indian nanotechnology company, Log9 Materials, is working extensively on Lithium Titanate Oxide (LTO) cell chemistry for developing fastest charging and longest lasting EV batteries for 2Ws, 3Ws, and 4Ws. “We are the first ones to use LTO chemistry in India and are also introducing our new product range based on Lithium Ferrous Phosphate (LFP) cell chemistry with cooling management systems and thermal management systems in place for mid mile logistics sector,” said Co-Founder and Director of Log9.
Besides, iPower Batteries recently introduced the RugPro battery series, utilising LMFP chemistry. “This combines the advantages of both NMC and LFP technologies. Like NMC, it offers a high energy density, while also possessing the high thermal stability characteristic of LFP. We believe that this new chemistry will play an important role in the Indian EV market,” asserts Aggarwal.
Making Cell Production Greener
Cell production remains the largest greenhouse gas (GHG)–emitting step in battery production.
When asked about how manufacturers can make cell production greener, to which Sharma said, “our cell production process involves aqueous processing of cell electrodes by eliminating the use of toxic solvents which in turn minimises energy utilisation and harmful gas emissions.” Further, he noted that the company works on a no-Cobalt chemistry that reduces the carbon emissions by 50 per cent. Also, for faster and efficient production of cells with optimised energy consumption, Log9 is using tab-less technology for developing large cylindrical format cells.
Battery Swapping
With limited charging infrastructure in India, battery swapping is seen as a viable alternative to it. One of the primary advantages of battery swapping is the significantly reduced recharge time compared to conventional charging methods. While charging an EV can take hours, battery swapping can be completed in a matter of minutes. This quick turnaround time allows drivers to get back on the road faster, making it a viable option for those who require frequent and efficient recharging.
For Pankaj Sharma, battery swapping is not a promising route for keeping the vehicles on the road. Specially not in rural areas where the density of the vehicles is significantly lower than in urban centres.
“Swapping requires a very high density of vehicles of the same type using the same batteries for it to be viable, it’s not even possible in urban centres, forget rural India,” he added.
Sharma feels that battery swapping is an operational solution to today’s cell and battery level technological constraints. “While it aids faster adoption of EVs, swapping does very little to solve the inherent technological challenge of finding the right energy and power density mix for an economically viable and scalable solution,” he highlighted.
“From the high CAPEX that it entails to operational complexities arising out of different battery models, to concerns around safety given swappable packs must be light enough for consumers to carry and space efficient, leaving little room for active cooling – battery swapping comes with more risks and challenges than a benefit to the customer,” Sharma noted further.
Skill Development
The scope of skill development in battery manufacturing is substantial, given the growing demand for batteries across various industries. Battery manufacturing requires a deep understanding of battery chemistry, materials, and production processes.
While there is a huge gap in terms of employing skilled workers, to bridge this gap, iPower Batteries has initiated a comprehensive skill upscaling program aimed at offering battery analysis and repair training to people. Upon completion of this training program, participants will be equipped with the necessary knowledge and practical skills to either establish iPower battery service centres or pursue employment opportunities within the electric vehicle (EV) and battery industry.
