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Visualizing the Decline of Copper Usage in EVs

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Visualizing the Decline of Copper Usage in EVs

Copper intensity in passenger battery electric vehicles (BEVs) has steadily decreased over the last decade, driven by numerous technological advancements alongside increasing usage of alternative materials such as aluminum.

In this graphic, we visualize the evolution of copper demand in various subcomponents of passenger battery electric vehicles (BEVs) from 2015 to 2030F, along with total global copper demand driven by EVs for the same period. This data comes exclusively from Benchmark Mineral Intelligence.

Copper Intensity Per Car

According to Benchmark Mineral Intelligence, the copper intensity per vehicle is expected to decline by almost 38 kg, from 99 kg in 2015 to 62 kg by 2030.

YearWiringMotorCopper FoilBusbarAuxiliary MotorCharging CableTotal
201530841.2613.232.873.9699.32
201629838.6813.372.853.9295.82
201728732.6712.722.843.9087.13
201827726.3911.872.823.8878.96
201926728.0010.852.783.8278.45
202025724.7110.242.733.7673.44
202124625.279.292.693.7070.95
202223728.448.562.653.6473.29
202322729.878.122.613.5873.18
2024F21727.737.672.563.5269.48
2025F20727.797.192.522.5167.01
2026F20727.786.632.483.4167.30
2027F19827.556.152.443.3566.49
2028F18826.775.702.403.3064.17
2029F18826.175.512.393.2863.35
2030F17825.635.442.373.2661.70

One of the most significant factors driving this decline is thrifting, where engineers and manufacturers continuously improve the efficiency and performance of various components, leading to reduced copper usage. A key example of this is in battery production, where the thickness of copper foil used in battery anodes has significantly decreased.

In 2015, Benchmark estimated copper foil usage was just over 41 kg per vehicle (at an average thickness of 10 microns), but by 2030, it is projected to fall to 26 kg as manufacturers continue to adopt thinner foils.

Similarly, automotive wiring systems have become more localized, with advances in high-voltage wiring and modular integration allowing for reduced copper content in wiring harnesses.

Copper used in wiring has dropped from 30 kg per vehicle in 2015 to a projected 17 kg by 2030.

Newer, more compact power electronics and improved thermal management in motors and charging cables have also contributed to the reduction in copper usage.

Substitution has also played a role, with alternatives such as aluminum increasingly being used in components like busbars, wiring harnesses, and charging cable applications.

Aluminum’s lighter weight and lower cost have made it a practical alternative to copper in specific applications, though the additional space required to achieve the same level of conductivity can limit its use in certain cases.

Benchmark estimates that copper used in automotive wire harnesses has declined by 30% between 2015 and 2024.

The Road Ahead

Despite reductions in per-vehicle copper usage, the outlook for copper demand from the EV sector remains strong due to the sector’s growth.

YearEV Sector Copper Demand (tonnes)
201556K
201682K
2017111K
2018166K
2019179K
2020237K
2021447K
2022696K
2023902K
2024F1.0M
2025F1.2M
2026F1.5M
2027F1.7M
2028F2.0M
2029F2.2M
2030F2.5M

Benchmark’s analysis indicates that by 2030, copper demand driven by EVs alone will exceed 2.5 million tonnes, securing copper’s critical role in the transition to a low-carbon future.

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Energy Shift

Charted: Coal Still Dominates Global Electricity Generation

Fossil fuels account for nearly 60% of power generation.

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Bar chart showing coal as the main electricity generation source in 2024

Charted: Coal Still Dominates Global Electricity Generation

This was originally posted on our Voronoi app. Download the app for free on iOS or Android and discover incredible data-driven charts from a variety of trusted sources.

Key Takeaways

  • Fossil fuels made up nearly 60% of 2024 electricity generation.
  • Coal accounts for 35% of total power generation.

Fossil Fuels Still Power Most of the World

Global energy demand grew faster than average in 2024, driven by rising electricity use across sectors. The power sector led the surge, with demand growing nearly twice as fast as overall energy use—fueled by increased cooling needs, industrial activity, transport electrification, and the expansion of data centers and AI.

Despite a growing push toward cleaner energy sources, coal remains the leading source of electricity generation worldwide. In 2024, fossil fuels accounted for nearly 60% of global power generation, with coal alone contributing 35%, according to the International Energy Agency.

While renewable energy continues to expand, making up about one-third of total electricity production, the global energy mix still leans heavily on traditional sources.

CountryCoalNatural GasOilRenewablesNuclear
🇮🇳 India73.4%3.3%0.2%20.5%2.6%
🇨🇳 China58.4%3.2%0.1%33.9%4.4%
🇺🇸 U.S.15.6%42.6%0.7%23.3%17.9%
🇪🇺 EU10.7%15.6%1.5%48.7%23.6%
🌍 Global34.5%21.8%2.4%32.1%9.1%

In emerging markets and developing economies, coal continues to be the backbone of power systems. China, the world’s largest energy consumer, generated nearly 60% of its electricity from coal. In India, coal’s dominance is even more pronounced, providing close to three-quarters of all electricity produced.

In contrast, advanced economies are increasingly relying on cleaner sources. In 2024, the European Union made significant strides in renewable energy adoption—nearly half of its electricity came from renewables, far exceeding the global average.

In the United States, natural gas led the power mix, accounting for over 40% of electricity generation in 2024. President Trump’s pro-coal policies and the surge in energy demand from AI innovation are expected to boost coal production in the U.S. over the next few years.

Learn More on the Voronoi App 

If you enjoyed this topic, check out this graphic that shows how 36 companies are responsible for half of the fossil fuel and cement CO2 emissions.

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Energy Shift

How the Largest Importers of Russian Fossil Fuels Have Changed (2022 vs. 2025)

Despite sanctions against Moscow, the EU remains a key consumer of Russian fossil fuels.

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This graphic highlights the largest importers of Russian fossil fuels, based on the daily flow of oil and gas

How the Largest Importers of Russian Fossil Fuels Have Changed (2022 vs. 2025)

This was originally posted on our Voronoi app. Download the app for free on iOS or Android and discover incredible data-driven charts from a variety of trusted sources.

Since the war in Ukraine began on February 24, 2022, Russia has earned $915 billion from fossil fuel exports, with EU countries accounting for over $223 billion.

Despite sanctions against Moscow, the EU remains a key consumer of Russian fossil fuels.

This graphic highlights the largest importers of Russian fossil fuels, based on the daily flow of oil and gas, using data from the CREA Fossil Fuel Tracker as of March 2025.

China Becomes the Biggest Buyer

In June 2022, China overtook the EU as the largest importer of Russian fossil fuels. Today, China imports nearly six times more than the EU. India and Turkey have also emerged as major buyers.

Country2022-01-14 (tonnes)2025-03-13 (tonnes)
🇨🇳 China435,025607,288
🇪🇺 EU928,998104,646
🌍 Others244,945275,747
🇮🇳 India28,907344,848
🇹🇷 Turkey138,860239,662
🇰🇷 South Korea93,26730,255
🇺🇸 United States33,4680
🇬🇧 UK49,0620

Meanwhile, imports from the U.S. and UK, which were relatively small before the invasion, have dropped to zero.

EU Reliance on Russian Fuel

A report released by Ember estimates that European purchases of Russian gas amounted to €21.9 billion ($23.6 billion) in 2024.

Additionally, data collected by Kpler and analyzed by POLITICO Europe revealed that in the first 15 days of 2025, the 27 EU countries imported a record-high 837,300 metric tons of liquefied natural gas (LNG) from Russia. This has raised concerns that billions of dollars could be fueling Moscow’s war in Ukraine.

Russia’s Position in Global Oil Production

Russia remains one of the world’s top oil producers, frequently competing with Saudi Arabia for the second spot behind the United States.

Following the fall of the Soviet Union, Russia’s oil industry was privatized, but in 2021, the state forced a consolidation and restructuring of the sector. Today, Gazprom, Rosneft, and Lukoil are Russia’s leading oil and gas producers.

Learn More on the Voronoi App 

If you enjoyed this topic, check out this graphic that shows Ukraine’s mineral resources.

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