Rho Motion on the 2nd of October opened its Rho Motion Live: North America event in Ohio, co-hosted with JobsOhio, the state’s unique private economic development corporation.

Adam Panayi, Managing Director at Rho Motion opened the day, thanking JobsOhio for invitation to Colombus, Ohio. Jonathon Bridges Managing Director at JobsOhio, welcomed delegates to Colombus, giving an overview of JobsOhio. It has a focus on attracting the right companies and industry sectors to the Mid-West. In the battery space this has included Ultium cell, the Honda-LG JV and many others, transforming the trajectory of Ohio, becoming a hub of industry and jobs creation.

Discussions throughout the day covered the North American EV Market outlook, battery recycling, rare earth supply chains, US electrification challenges, the scaling of gigafactories, battery technologies and supply chain logistics.Companies participating included: GM, Honda, SK Ecoplant, Momentum Technologies, Cyclic Materials, LG Energy Solution, Samsung SDI, Echion Technologies, Xerion Advanced Battery Corp as well as Kuehne + Nagel Inc.

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Rho Motion Live: North America

Session 1 – North American EV Market: What Happens Next? – Rho Motion, General Motors, Honda

Will Roberts, Automotive Research Lead, Rho Motion:

  • EV sales are mixed globally, strong in China, weak in the EU (-4% YTD by August), while the US market has shown slow but steady growth.
  • The US market is trending to larger vehicles with bigger battery packs, 100+ kWh which is driving increased battery demand.
  • BEV prices in the US remain high, though the price premium over ICE vehicles is less compared to Europe.
  • The upcoming US election could have large effects on EV sales and battery demand in the US

Michael Maten, Director, EV Policy and Regulatory Affairs, General Motors:

  • GM currently has 12 EV models, all offering around a 300-mile range. Has seen strong demand for the Equinox model.
  • GM’s EV sales are up 60% YoY in Q3; by 2025, it will release a new affordable model priced at USD 30,000 (USD 20,000 with tax credits).
  • GM’s Ultium facilities are contributing to US cell production, However, overcapacity in Asia and low commodity prices make US investment difficult, this as well as current market uncertainty hampers project funding.

Dr Christopher Brooks, Chief Scientist, Honda:

  • Honda’s “Triple Action to Zero” strategy includes clean energy, carbon neutrality, and resource circularity across its business divisions, from batteries to SAFs.
  • Honda will focus on electrifying small mobility products and EVs in the near term, with hybrids playing a significant role.
  • It targets 40% EVs by 2030 in developed countries and 100% by 2040. The company is prioritising vertical integration and software development.

Session 2 – Battery Recycling – Rho Motion, SK Ecoplant, Momentum Technologies

Mina Ha, Recycling Research Lead, Rho Motion:

  • Black mass supply is expected to grow by 48% by the end of 2024, primarily from production scrap, increasing from 61% in 2022 to 64% in 2023.
  • Nearly half of the 2023 feedstock came from China; this year sees more variation, with Europe and North America contributing significantly
  • The global EoL inflection point for EVs is delayed to 2031 due to the EV slowdown, however Asia will likely see this earlier.
  • Pre-treatment capacity is forecast to rise sharply from 24% in 2024 to 64% in 2025. China’s capacity, however, already exceeds current feedstock levels.
  • Overcapacity in China is taking demand from other regions
  • Regional chemistry preferences influence recycling trends: LFP dominates in China, while NCM is prevalent in the West. LFP recycling outside China remains at pilot scale.

Sangjune Han, Director, SK Ecoplant:

  • Feedstock is critical for recyclers, who do not control its supply.
  • SK Ecoplant’s key strategies:
    • Maximise waste collection.
    • Set collection rates and minimum recycled content.
    • Ensure traceability, reliability, and transparency via audits and standards, involving stakeholders like governments and OEMs.
  • SK Ecoplant is collaborating with SK TES to address complex EV recycling challenges, particularly for parts like converters and motors.

Mahesh Konduru, CEO, Momentum Technologies:

Momentum Technologies is focused on the refining aspect of battery recycling, using a low-cost, modular platform and solvent extraction process.

  • It is currently refining at demo scale in Texas, with plans for a commercial plant in Ohio. Aiming for 95-98% purity recovery.
  • Its technology offers low CAPEX, flexible inputs, and scalability, with potential applications beyond batteries.

Session 3 – Creating a Circular Supply Chain for Rare Earth Elements – Rho Motion, Cyclic Materials

Will Roberts, Automotive Research Lead, Rho Motion:

  • Motor recycling is set to increase, especially in North America, where tariffs are being introduced. However, technology, not tariffs, is the main barrier.
  • Magnet demand from EVs is growing.

Patrick Nee, SVP Strategic Partnerships, Cyclic Materials:

  • Rare earth materials are essential for energy transition but are hard to source due to limited availability and long mine development timelines.
  • China dominates the midstream production, and recycling rates are low, less than 1%, due to technical challenges like magnets being lost in furnace slag.
  • Pilot-scale factories are being developed globally to address recycling, focusing on EV motors and damaged vehicles.
  • Recycling offers substantial ESG benefits, including a 63% reduction in carbon footprint and 95% lower water consumption.

Session 4 – Turbulent but Certain Path Towards Electrification – Rho Motion, LG Energy Solution

Robert H. Lee, Corporate Executive Vice President and Head of North America, LG Energy Solution:

Challenges to electrification:

  • Range anxiety persists, but most EV users don’t require daily charging.
  • Charging infrastructure is key, with private networks dominating, and fast charging only covering a small share.
  • BEV costs in China are already lower than ICE vehicles. LG is working on USD30,000, 300-mile EVs to boost adoption.

LG Energy Solution’s targets for cost reduction:

It is looking at innovations like solid-state batteries and dry electrodes in the longer term, targeted for 2028, to lower costs, but currently efforts are concentrated on ramping up facilities to meet growing demand

Session 5 – Gigafactories at Scale: Samsung SDI

Joseph Pittel, Vice President, Legal and Public Affairs, Samsung SDI America Inc.:

  • The battery market is seeing a shift in focus towards mid-nickel and mixed applications for battery solutions.
  • All solid-state batteries (ASB) are seen as the solution to safety issues. Samsing has a pilot line already operational in Korea.
  • While ASB is the “end game,” current focus is on cost competitiveness in the market.
  • Competition with China is fierce, with China leading in cost competitiveness. Samsung supports the IRA but argues for stable policies to support long-term investment.
  • Samsung’s Starplus energy plant is under construction, with all output is committed to Stellantis.

Session 6 – Battery Technology Roadmaps – Echion Technologies, Xerion Advanced Battery Corp

Jean de la Verpilliere, CEO, Echion Technologies:

  • Echion’s XNO anode powder offers a balance between energy density and charge rate and is being adopted by cell manufacturers like Leclanché, amongst others.
  • The technology is slow to adopt but has high potential in industries such as mining.

Dr. John Busbee, CEO, Xerion Advanced Battery Corp.:

  • Xerion is a 100% US-owned battery cell manufacturer currently with pilot scale facilities.
  • It is moving to low-rate production by January 2025 with plans for a 1GW facility in Ohio.
  • Its technologies, DirectPlate and StructurePore technologies, significantly reduces manufacturing costs, does not need battery grade materials and improve charging speed and cycle life.

Session 7 – Logistics Showcase: Optimising Supply Chains Across Continents with Kuehne + Nagel Inc.

Edward Keith, Head of Consulting, Rho Motion

Ian Slaven, Vice President, Global Vertical Lead Automotive, Kuehne + Nagel Inc.

Molly Exner, Director, Automotive + New Mobility, Kuehne + Nagel Inc.

Valerie Hall, Director, Automotive + New Mobility, Kuehne + Nagel Inc.

  • The logistics market for EVs is still developing, requiring support for clients to navigate complexities and manage expectations regarding lead times.
  • Unplanned supply chain disruptions due to COVID-19, geopolitical issues, and high interest rates have prompted companies to shift operations from Asia to the US, increasing transportation costs and tariffs.
  • Constant regulatory changes are affecting black mass shipping, necessitating logistics providers to stay informed and collaborate closely with clients.
  • Companies need to proactively understand regulations, as many clients expect quick results despite the fluidity and complexity of logistics.
  • Shipping challenges for batteries, particularly damaged or used ones, underscore the need for domestic sourcing and recycling, as these cannot be shipped via air or ocean freight due to safety issues.