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Breaking Down the Cost of an EV Battery Cell

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Cost of a lithium-ion battery cell

Breaking Down the Cost of an EV Battery Cell

As electric vehicle (EV) battery prices keep dropping, the global supply of EVs and demand for their batteries are ramping up.

Since 2010, the average price of a lithium-ion (Li-ion) EV battery pack has fallen from $1,200 per kilowatt-hour (kWh) to just $132/kWh in 2021.

Inside each EV battery pack are multiple interconnected modules made up of tens to hundreds of rechargeable Li-ion cells. Collectively, these cells make up roughly 77% of the total cost of an average battery pack, or about $101/kWh.

So, what drives the cost of these individual battery cells?

The Cost of a Battery Cell

According to data from BloombergNEF, the cost of each cell’s cathode adds up to more than half of the overall cell cost.

EV Battery Cell Component% of Cell Cost
Cathode51%
Manufacturing and depreciation24%
Anode12%
Separator7%
Electrolyte4%
Housing and other materials3%

Percentages may not add to 100% due to rounding.

Why Are Cathodes so Expensive?

The cathode is the positively charged electrode of the battery. When a battery is discharged, both electrons and positively-charged molecules (the eponymous lithium ions) flow from the anode to the cathode, which stores both until the battery is charged again.

That means that cathodes effectively determine the performance, range, and thermal safety of a battery, and therefore of an EV itself, making them one of the most important components.

They are composed of various metals (in refined forms) depending on cell chemistry, typically including lithium and nickel. Common cathode compositions in modern use include:

  • Lithium iron phosphate (LFP)
  • Lithium nickel manganese cobalt (NMC)
  • Lithium nickel cobalt aluminum oxide (NCA)

The battery metals that make up the cathode are in high demand, with automakers like Tesla rushing to secure supplies as EV sales charge ahead. In fact, the commodities in the cathode, along with those in other parts of the cell, account for roughly 40% of the overall cell cost.

Other EV Battery Cell Components

Components outside of the cathode make up the other 49% of a cell’s cost.

The manufacturing process, which involves producing the electrodes, assembling the different components, and finishing the cell, makes up 24% of the total cost.

The anode is another significant component of the battery, and it makes up 12% of the total cost—around one-fourth of the cathode’s share. The anode in a Li-ion cell is typically made of natural or synthetic graphite, which tends to be less expensive than other battery commodities.

Although battery costs have been declining since 2010, the recent surge in prices of key battery metals like lithium has cast a shadow of doubt over their future. How will EV battery prices evolve going forward?

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Electrification

Visualizing the EU’s Critical Minerals Gap by 2030

This graphic underscores the scale of the challenge the bloc faces in strengthening its critical mineral supply by 2030.

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This graphic underscores the scale of the challenge the EU faces in strengthening its critical mineral supply chains under the Critical Raw Material Act.

Visualizing EU’s Critical Minerals Gap by 2030

The European Union’s Critical Raw Material Act sets out several ambitious goals to enhance the resilience of its critical mineral supply chains.

The Act includes non-binding targets for the EU to build sufficient mining capacity so that mines within the bloc can meet 10% of its critical mineral demand.

Additionally, the Act establishes a goal for 40% of demand to be met by processing within the bloc, and 25% through recycling.

Several months after the Act’s passage in May 2024, this graphic highlights the scale of the challenge the EU aims to overcome. This data comes exclusively from Benchmark Mineral Intelligence, as of July 2024. The graphic excludes synthetic graphite.

Securing Europe’s Supply of Critical Materials

With the exception of nickel mining, none of the battery minerals deemed strategic by the EU are on track to meet these goals.

Graphite, the largest mineral component used in batteries, is of particular concern. There is no EU-mined supply of manganese ore or coke, the precursor to synthetic graphite.

By 2030, the European Union is expected to supply 16,000 tonnes of flake graphite locally, compared to the 45,000 tonnes it would need to meet the 10% mining target.

Metal 2030 Demand (tonnes)Mining (F)Processing (F)Recycling (F)Mining Target Processing Target Recycling Target
Lithium459K29K46K25K46K184K115K
Nickel403K42K123K25K40K161K101K
Cobalt94K1K19K6K9K37K23K
Manganese147K0K21K5K15K59K37K
Flake Graphite453K16K17KN/A45K86KN/A

The EU is also expected to mine 29,000 tonnes of LCE (lithium carbonate equivalent) compared to the 46,000 tonnes needed to meet the 10% target.

In terms of mineral processing, the bloc is expected to process 25% of its lithium requirements, 76% of nickel, 51% of cobalt, 36% of manganese, and 20% of flake graphite.

The EU is expected to recycle only 22% of its lithium needs, 25% of nickel, 26% of cobalt, and 14% of manganese. Graphite, meanwhile, is not widely recycled on a commercial scale.

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Visualizing China’s Cobalt Supply Dominance by 2030

Chinese companies are expected to control 46% of the cobalt supply by 2030.

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This graphic visualizes the total cobalt supply from the top ten producers in 2030, highlighting China's dominance.

Visualizing China’s Cobalt Supply Dominance by 2030

Chinese dominance over critical minerals used in technologies like smartphones, electric vehicles (EVs), and solar power has become a growing concern for the U.S. and other Western countries.

Currently, China refines 68% of the world’s nickel, 40% of copper, 59% of lithium, and 73% of cobalt, and is continuing to expand its mining operations.

This graphic visualizes the total cobalt supply from the top 10 producers in 2030, highlighting China’s dominance. The data comes from Benchmark Mineral Intelligence, as of July 2024.

Cobalt production (tonnes)Non-Chinese Owned
Production
Chinese Owned
Production
2030F (Total)2030F (Share)
🇨🇩 DRC94,989109,159204,14867.9%
🇮🇩 Indonesia23,28825,59148,87916.3%
🇦🇺 Australia7,07007,0702.4%
🇵🇭 Philippines5,27005,2701.8%
🇷🇺 Russia4,83804,8381.6%
🇨🇦 Canada4,51004,5101.5%
🇨🇺 Cuba4,49604,4961.5%
🇵🇬 Papua New Guinea5413,0673,6081.2%
🇹🇷 Turkey2,83502,8350.9%
🇳🇨 New Caledonia2,79902,7990.9%
🌍 ROW10,3361,90112,2374.1%
Total160,974139,718300,692100.0%

China’s Footprint in Africa

Cobalt is a critical mineral with a wide range of commercial, industrial, and military applications. It has gained significant attention in recent years due to its use in battery production. Today, the EV sector accounts for 40% of the global cobalt market.

The Democratic Republic of Congo (DRC) currently produces 74% of the world’s cobalt supply. Although cobalt deposits exist in regions like Australia, Europe, and Asia, the DRC holds the largest reserves by far.

China is the world’s leading consumer of cobalt, with nearly 87% of its cobalt consumption dedicated to the lithium-ion battery industry.

Although Chinese companies hold stakes in only three of the top 10 cobalt-producing countries, they control over half of the cobalt production in the DRC and Indonesia, and 85% of the output in Papua New Guinea.

Given the DRC’s large share of global cobalt production, many Chinese companies have expanded their presence in the country, acquiring projects and forming partnerships with the Congolese government.

According to Benchmark, Chinese companies are expected to control 46% of the global cobalt mined supply by 2030, a 3% increase from 2023.

By 2030, the top 10 cobalt-producing countries will account for 96% of the total mined supply, with just two countries—the DRC and Indonesia—contributing 84% of the total.

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