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At the end of January 2024, keen-eyed residents of the Belgian capital Brussels may have noticed something different about the familiar national postal service: it began delivering some mail in an electric vehicle with a detachable cargo compartment.

The move by Bpost is part of a research project that received EU funding to improve city life across Europe by cleaning up road transport and reducing traffic bottlenecks. Called URBANIZED, the project began in January 2021 and will run through June 2024.

New deliveries 

Bringing together industry, research and university representatives from seven EU countries, URBANIZED has developed a fully electric vehicle for urban deliveries of postal, retail and other services. 

Manufactured in the Italian city of Padua by Alkè, the vehicle resembles a small lorry or moving van whose detachable cargo section has roll-up doors on three sides. The doors cover almost the whole sides, facilitating access to the bay.

Without the cargo compartment, the vehicle is 4.2 metres long, almost 1.4 metres wide and nearly 2 metres high. It has a range of 200km and an on-board charger that takes six hours to be replenished. 

"The initial intention is to extensively test the prototype in real conditions," says Chris Deweirt, project manager at Bpost. 

So-called last-mile deliveries by businesses such as Bpost are responsible for 30% of all city traffic. This share rises to 80% during peak hours.

A boom in online shopping has led to packages being transported from warehouses to front doors by trucks, vans and motorbikes. The result is more air pollution and traffic congestion in cities. 

Modular matters

A key challenge is enabling a single vehicle to perform two services – something known as modularisation. 

This means that, for example, a vehicle can be used as a postal service in the morning and then be disassembled and equipped with, say, a fridge for food delivery in the afternoon.

 
'Adoption of electric light commercial vehicles – and of the URBANIZED vehicle more specifically – would help Europe reduce its carbon emissions.' Salvador Ruiz, URBANIZED

 

Modularisation would help offset the relatively high cost of batteries used in road transport, making electric-vehicle deliveries more commercially appealing.

"What is very expensive is the battery system," says Salvador Ruiz, who runs URBANIZED and is a project manager at automotive-engineering company Applus IDIADA in Spain.

He says that having one vehicle with interchangeable cabins can cut costs by half.

The project is championing electric light commercial vehicles that are adaptable and easily swappable.

The prototype being tested by Bpost is a step in that direction.

The overall goal of URBANIZED is to design a small, modular electric vehicle for urban freight transport, or UFT. These would be purpose-designed to improve operations compared with current vehicles of all kinds used for last-mile delivery.

Emission and cost cuts

Ruiz says modular electric UFT vehicles could reduce total road-transport emissions of carbon dioxide (CO2) by at least 3%.

And URBANIZED’s proposed solutions, when applied at fleet level, could make deliveries at least 51% more affordable than with a standard electric-vehicle fleet, according to the project. 

The last mile accounts for 15% to 25% of all vehicle kilometres travelled, according to Ruiz. He said freight contributes between 20% and 40% of urban transport’s emissions of CO2, the main greenhouse gas responsible for climate change.

The EU is seeking to become climate-neutral by 2050 and, to help achieve that goal, has agreed to ban the sale beginning in 2035 of new cars and vans powered by petrol or diesel.

"Adoption of electric light commercial vehicles – and of the URBANIZED vehicle more specifically – would help Europe reduce its carbon emissions," says Ruiz. 

Test runs

The Bpost trial is due to last for one month, centres on the company’s Brussels mail hub and involves several daily postal rounds in various municipalities. 

A prototype electric vehicle with a detachable cargo bay. © URBANIZED 

The vehicle, called ASTRID, is being used on seven of 182 rounds in central districts including Ixelles, Saint-Gilles and Uccle. Bpost says the test has encountered no significant troubles to date. 

While the current focus is on logistics in Brussels, the company is weighing the eventual possibility of deploying the URBANIZED prototype more widely in Belgium.

"Bpost naturally also wants to check whether such a vehicle is a suitable long-term option for the delivery of mail and parcels," says Deweirt. 

Cargo bikes

While Bpost tries out URBANIZED’s prototype in Brussels, a German company called ONOMOTION is further developing an electric vehicle that combines the flexibility of a bicycle with the durability of a van.

Called the Pedal Assisted Transporter, it is a cross between a bike and a capsule-sized car. Narrow and streamlined, the electric cargo bike has a fully covered driver’s cab as protection against bad weather.

 
'We identified the last mile of logistics as a crucial area for improvement.' Beres Seelbach, ONO

 

It was tested in an EU-funded research project run by ONOMOTION. Called ONO, the project lasted for two years through July 2022 and highlights the EU’s goal of supporting new businesses that green the economy and create jobs.

The cargo bike is meant to improve courier, express and parcel transport in city centres by providing an adaptable and environmentally friendly option for last-mile deliveries. 

"We identified the last mile of logistics as a crucial area for improvement," says Beres Seelbach, co-founder of ONOMOTION. "It is often the most challenging and costly part of the delivery process."

While the cargo bike is market-ready, the company is working on lowering the cost and making maintenance and repair easier. 

Chinese inspiration

Seelbach was inspired to tackle this challenge in 2004 when he was studying in Chengdu in western China. There, in the fourth-biggest Chinese city, he saw the widespread use – and advantages – of electric-mobility options and wondered why relatively few existed in his native Germany. 

After returning from China, Seelbach set up his own electric-vehicle company in 2009. He later founded ONOMOTION with two previous business partners.

ONOMOTION now has clients that include German parcel-delivery company Hermes, global shipper UPS and Belgium-based international courier DPD, all of which use the Pedal Assisted Transporter.

The company recently introduced services in Paris and opened a production facility in Berlin. 

Seelbach says that ONOMOTION plans to enter other markets abroad including Austria and the UK. While the company stands to gain from these plans, he says city residents will too.

"Once our project reaches its full potential, consumers will benefit from cleaner air due to reduced emissions, less congested roads and more efficient delivery services," says Seelbach.

Post and parcel delivery services in cities go green

There are two distinctive types of electric buses making their way along Nanjing Xi Lu, one of Shanghai's busiest roads.

The first is a fleet of blue trolleybuses that serve bus route number 20, a line set up by a British-run transport company in 1928. They use poles on their roofs to receive electricity from wires overhead and have kept the route running in this way for nearly a century.

But while the historic trolleybuses are a reminder of Europe's past technological innovation, the new buses swooshing alongside them are symbols of China's contemporary net-zero ambition.  

These sleek and modern electric buses, powered by lithium batteries not wires, were rolled out in Shanghai in their thousands beginning in 2014. Compared to the once ubiquitous diesel-fuelled buses, which made loud 'vroom-vroom' engine sounds and belched out black smoke from their tailpipes, the e-buses dominating Shanghai's streets today are quiet, smoke-free and stylish to look at. They also drive smoothly, particularly when they start and stop.

These sleek buses are now ubiquitous across much of China, but their status as a green transport icon was not always assured. As they shuttle back and forth along their bustling daily routes, these vehicles are having a profound influence on not just China's rapid EV transition, but the world's. 

Electric buses have a long history in China, dating back to the 1920s – but China's new generation of electric buses is world-leading in the 21st century. Image: Getty Images. 

An uphill start

The country's decision to spur the manufacturing and use of e-buses was primarily a strategy for industrial growth, then a part of its efforts to curb air pollution. It was only after the government's 2020 pledge to become carbon neutral before 2060 that promoting electric vehicles has become an important part of its climate goals. Yet it appears to be working. 

China now boasts the world's largest market for e-buses, making up more than 95% of global stock

 

The most recent data available shows that China in 2018 was still the second largest source of carbon dioxide (CO2) emissions in the global transport sector, responsible for 11%, and behind only the United States, which accounted for 21%. However, in order to help reduce transport emissions around the world, the International Energy Agency has called for policies to encourage public transport and electric vehicles – and China's e-bus roll out is helping achieve both. 

After about two decades of government support, China now boasts the world's largest market for e-buses, making up more than 95% of global stock. At the end of 2022, China's Ministry of Transport announced that more than three-quarters (77% or 542,600) of all urban buses in the country were "new energy vehicles", a term used by the Chinese government to include pure electric, plug-in hybrids, and fuel cell vehicles powered by alternative fuels such as hydrogen and methanol. In 2022, about 84% of the new energy bus fleet was pure electric. 

The speed of this transition was remarkable. In 2015, 78% of Chinese urban buses still used diesel or gas, according to the World Resources Institute (WRI). The NGO now estimates that if China follows through on its stated decarbonisation policies, its road transport emissions will peak before 2030.

China is also home to some of the world's biggest electric bus manufacturers, such as Yutong, which has been raking up orders across China, Europe, and Latin America.

"China has really been at the forefront of success in conversion of all vehicles to electric vehicles, especially buses," says Heather Thompson, chief executive officer of the Institute for Transportation and Development Policy (ITDP), a non-profit focusing on sustainable transport solutions. "The rest of the world is trying to do the same, but I think China is really out ahead."

So how did China make this world-leading leap? 

A new track

At the time of China's 2001 entry into the World Trade Organization, the international automotive industry was dominated by European, US and Japanese brands. These companies had spent decades perfecting internal combustion engine technology. To compete, Beijing decided to find a new track for its auto industry: making cars that did not use conventional engines.

That same year, the central government launched the so-called 863 plan for EV research and development. There were numerous practical challenges, however, in the way of mass electrification. Not many manufacturers were making new energy vehicles, buyers were few and there was a lack of charging infrastructure in existence. The answer? Buses. 

The regular nature of the bus route lent itself to electrification, with the opportunity to charge vehicles overnight in a planned spot. Image: Getty Images. 

"The Chinese government adopted a very smart strategy," says Liu Daizong, ITDP's East Asia director. "They realised quite early on that they should drive [the EV industry] through electric buses," he notes, since their public service status meant Beijing "could have a strong hand on their electrification".

There were also technological reasons to make buses the spearhead of an electric vehicle revolution. "Bus routes were fixed. This means when an electric bus finished a round, it could return to the depot to recharge," explains Xue Lulu, a mobility manager at the World Resources Institute (WRI) China. The typical daily mileage of a Chinese bus ­– 200km – was a realistic range for battery makers to meet.

Extending the line

China first showed its global EV ambitions at the 2008 Olympics in Beijing. Athletes, guests and spectators were transported around the stadiums by the Ministry of Technology's fleet of 595 'green' vehicles.

The following year, the country began its large-scale rollout of new energy buses, with the Ten Cities and Thousand Vehicles programme. Over three years, the programme aimed to provide 10 cities with financial subsidies to promote 1,000 public-sector new energy vehicles in each, annually. Its goal was to have 10% new energy vehicles in the country by the end of 2012.

Strong policy support from both central and regional governments "gave manufacturers confidence in setting up production lines and stepping up research efforts", says Liu.

By the end of 2012, the programme had reached 25 cities and 27,432 new energy vehicles had been rolled out, reported China Auto News, a newspaper affiliated with state-owned People's Daily Group.

A technological innovation fund was also established by the central government to spur research and development into energy-saving and new energy automotive industry, according to the publication. By December 2013, the fund had awarded a total of 1.6bn yuan (€210m) to 25 projects from 24 companies. 

Together, these strong and consistent government signals encouraged Chinese manufacturers to expand their EV production capacity, bring down costs and improve their technologies. One such company was Build Your Dream, better known as BYD. The Shenzhen-based firm, the world's largest EV maker in 2022, ballooned its business a decade before by supplying electric buses and taxis for China's EV pilot cities.

Making it personal

Progress wasn't straightforward. The Ten Cities, A Thousand Vehicles programme even missed its original three-year, 30,000-vehicle target, with not enough cities showing interest. But a second factor also began pushing cities to embrace new energy buses: air pollution.

"Back then, most buses used diesel, which was a main source of nitrogen oxides (NOx) emissions," says Xue, referring to the air pollution that smothered Beijing and other Chinese cities in the early 2010s. Yet in 2013, a new plan from central government cited tackling air pollution as one of the reasons for rolling out EVs.

This addition proved to be critical: it not only connected EV uptake with people's health, it also indirectly tied the e-bus campaign to local officials' political performance, as the central government would soon hand air-quality targets to all provinces.

In Lvliang, a small city in the coal heartland of Shanxi Province, fleets of e-buses started to appear on the streets about this time, according to Wang Xiaojun, who grew up in the city and now lives in the Philippines, where he runs an NGO called People of Asia for Climate Solutions.

"In the '80s and '90s, there were no buses in Lvliang, only vehicles transporting coal. Most people walked everywhere," he says. As Lvliang started to grow, the local government set up bus routes that used oil-fuelled fleets, but by 2013, many of these had been replaced by electric ones, "most likely because of the pressure [the local government] faced over air pollution". 

The years 2013 and 2014 proved to be important for China's EV push. For the first time, the central government made EV purchase subsidies available to individual consumers, not just the public sector, opening the floodgate to private ownership. Additionally, it offered discounted electricity tariffs to bus operators to make sure the cost of running electric buses would be "significantly lower than" that of their oil or gas-powered equivalents.

The new economic push, plus local government's determination to battle air pollution, generated great enthusiasm for e-buses. By the end of 2015, the number of EV pilot cities rocketed from 25 to 88. In the same year, the central government set a target of 200,000 new energy buses on the road by 2020 and announced a plan to phase out its subsidies for fossil-fuel-powered buses. 

Intense air pollution across many Chinese cities added momentum to the switch to electric vehicles. Image: Getty Images. 

To further stimulate the market, many cities devised various local policies on top of national incentives. For example, Shenzhen, a southern city with a population of more than 17 million, encouraged government agencies to work with private companies to create a full range of renting mechanisms for bus operators.

The battery accounts for 40-50% of an e-bus's total cost, so such rental programmes were key, says ITDP's Liu. Under this method, a bus operator could rent a battery from a manufacturer through a third-party financial organisation, then pay the rent from the money it saved from not having to use more expensive diesel or gas.

Different cities' bus operators also designed different charging strategies. "Buses in Shenzhen had bigger batteries, so they normally charged overnight," says Xue, of WRI China. Between 2016 and 2020, Shanghai, another electric bus hub, subsidised the electricity e-buses used – regardless of the hours of the day – to give them more flexibility in charging.

Generous financial support did lead to problems. In 2016, an EV subsidy fraud shook China, with some bus operators found to have exaggerated the number of e-buses they had purchased. So that same year Beijing shifted its EV subsidy rules so bus operators could only receive financial support when a bus's mileage reached 30,000km.

And finally, one year later, the government announced the so-called dual-credit policy. This allowed new energy vehicle makers to rake up credits which they could sell for cash to those needing to offset 'negative credits' generated from making conventional cars.

As a result of these policies, by 2017 Shenzhen had become the first city globally to replace all of its buses to battery-powered vehicles – with a 2021 study showing that the move had "significantly reduced" greenhouse gas emissions and air pollution in the city. 

Congestion ahead

Growth of China's electric buses now seemed unstoppable. The market was expanding so quickly that in 2018 the government updated its 2020 target for new energy buses from 200,000 to 400,000 and decided it was time to gradually phase out their subsidies. 

There is one charging pillar for every 2.5 of China's 13.1 million new energy vehicles 

 

And it wasn't only China's buses that had benefitted.China's e-bus campaign helped create a big and stable market for its wider EV industry, brought down the costs and created economies of scale. In 2009, the year the e-bus campaign was rolled out, the total number of new energy vehicles sold stood at 2,300; by 2022, it was 6.9 millionanalysis by Huang Zheng, a researcher at the Institute for Internet Industry at Tsinghua University, suggests.

By 2022, the country had also built the world's largest EV charging network, with 1.8 million public charging stations – or two-thirds of the global total – and 3.4 million private equivalents. This means that on average, there is one charging pillar for every 2.5 of China's 13.1 million new energy vehicles.

So far, however, the Chinese cities with the most successful e-bus rollouts – such as Shenzhen, Beijing and Shanghai – all have moderate weather and are relatively flat. To take its e-bus campaign to the next level, China faces challenges.

For one thing, it is difficult to bring fleets to cities such as Hong Kong, which – like London – have double-deckers. These two-storeyed vehicles are "very hard" to electrify, as Xue puts it, because they are heavier, use more energy, and so need bigger batteries, reducing the number of passengers they can carry. One of the few electric double-deck models is produced jointly by BYD and ADL, a UK bus manufacturer.

Cold weather is a problem, too, as it can make a battery's charging time longer and its range shorter. The reason China has not achieved 100% electrification for its buses is its northern regions, which have harsh winters, says Xue.

A further challenge is that the current e-bus manufacturing process can be polluting and emissions-intensive, says Wang; from the mining of raw materials for batteries, such as nickel and lithium, to the production of the steel. The latter is one of the hardest sectors to decarbonise due to the use of coking coal, which not only provides high heat but also acts as an ingredient to enable chemical reactions.

To make e-buses truly 'green', they should also be charged with renewable power, says Wang. But last year coal power still accounted for 58.4% of China's energy mix, according to the China Electricity Council, a trade body. 

The global picture

Globally, however, China is now in a league of its own in uptake of e-buses. By 2018, about 421,000 of the world's 425,000 electric buses were located in China; Europe had about 2,250 and the US owned about 300. According to Alicia García Herrero, a senior fellow at Bruegel, a Brussel-based think tank, Europe has generally been "lagging" in providing "bulky" fiscal support for e-buses.

But earlier this year, the European Commission announced a zero-emission target for all new city buses by 2030. And some countries are increasing their overall funding for the transition.

In 2020, the European Commission approved Germany's plan to double its aid for e-buses to €650m, then again in 2021 to €1.25bn. And the UK, which last year had the largest electric bus fleet in Europe with 2,226 pure electric and hybrid buses, has announced another €153m to help bus operators buy zero-emissions fleets.

While it may be theoretically easy for other countries to kick-start their e-bus rollouts with government subsidies, as China did, a fast deployment also relies on manufacturing capacity and infrastructure, says Ran Ze, a director at the China Representative Office of Environmental Defense Fund, an international environmental advocacy non-profit. "This is something other countries, especially developing nations, will find it hard to copy."

Countries have thus responded to China's manufacturing lead in divergent ways. "While the US has opted for a more competitive angle by fostering its own e-bus production, regions like Latin America are more open to trade with China due to a more friendly trading setup through [China's] Belt and Road initiative," explains Liu.

In order to avoid direct competition from Chinese manufacturers, the US has come up with a "school-bus strategy", says Liu. The Chinese don't make the iconic yellow vehicles, so this could ignite American e-bus manufacturing and create a local industry chain, he suggests. Backed by the US Environmental Protection Agency's $5bn Clean School Bus Programme, the national effort has so far committed to providing 5,982 buses.

In contrast, many Latin American cities, such as the Colombian capital of Bogota and the Chilean capital of Santiago, are greening their traditional bus sectors with the help of Chinese manufacturers, who are the largest providers to the region.

In 2020, Chile became the country that had the most Chinese e-buses outside of China, and this year Santiago's public transport operator announced it has ordered 1,022 e-buses from Beijing-based Foton Motor, the biggest overseas deal the firm had received.

Chinese manufacturers are likely to receive a lot more orders from Chile and its neighbours in this decade. According to latest research by the global C40 Cities network, the number of electric buses in 32 Latin American cities is expected to increase by more than seven times by 2030, representing an investment opportunity of more than €10.5bn.

Thompson, of ITDP, says that a lot of successful Latin American cities have also taken a leaf out of the Chinese book on financing, with electricity companies contributing to the cost, "knowing that ultimately the buses are going to plug into their electricity grid", she says. 

China's remarkably rapid introduction of electric buses has put it front and centre of the global EV market. Image: Getty Images. 

In Europe, however, Chinese e-bus makers are likely to face increasing headwinds. EU policymakers have responded to China's dominance in EV manufacturing with an anti-subsidy investigation, after European Commission President Ursula von der Leyen said that the "global market is flooded with cheaper electric vehicles".

"Amid the global tide to build more resilient supply chains, many are trying to reduce their dependency on China," says García Herrero.

The fast lane to net zero

In June 2023, BloombergNEF forecast half of the world's buses to be entirely battery-powered by 2032, a decade ahead of cars. And by 2026, 36% and 24% of municipal bus sales in Europe and the US, respectively, are expected to be EVs as they begin to catch up with China, BloombergNEF said in a report. But in Thompson's view, the world still has a long way to go electrifying buses, especially in Latin America, Asia and Africa.

"In places like Africa, there are many buses on the streets, but they are not part of the formal public transportation system," she notes. "They are small minibuses that, maybe, were first being used in markets in Europe or Japan, and then exported to Africa."

To meet the global climate goals set by the Paris Agreement, simply switching the world's existing bus fleets might not be enough. According to ITDP, the cumulative greenhouse gas emissions from urban passenger transport globally must stay below the equivalent of 66 gigatonnes CO2 between 2020 and 2050 for the world to meet the 1.5C temperature goal. This emissions limit will only be possible when the world not only adopts electric buses, but goes through a broader shift away from private transport.

"We can't just focus on [replacing] the buses that exist, we need to actually get many, many more buses on the streets," says Thompson. She and her team estimate that the world would need about 10 million more buses through 2030, and 46 million more buses cumulatively through 2050, to make public transport good enough to have a shot at achieving the Paris Agreement. And all those buses will need to be electric.

In China therefore, even though EVs are being sold faster than ever, its central government has instructed cities to encourage public transport use, as well as walking and riding bikes.

Outside residential blocks in the megacity Shanghai, colourful posters showing an e-bus, a bike and a subway train remind passers-by to commute in a low-carbon manner. The main bus operator of another city, Heze, home to nearly nine million people, has also reportedly offered to customise bus routes to suit citizens' needs, such as bypassing schools.

In Wang's home town, meanwhile, which has a little more than three million residents, the local government has gone one step further and made all bus rides free. All citizens need to do is to swipe an app, with no charge, to get onto the bus. "My aunt loves taking buses now," says Wang. "She says it is so convenient."

Wang now believes that even though the manufacturing e-buses can be polluting, making them more accessible is the right way forward – for China and the world.

"Only then can [the government] take the next step – to make the buses' electricity sources, batteries and steel greener in the future," he says. 

Author: This article was written by Xiaoying You and first appeared on the BBC website Future Planet.

How China's buses shaped the world's electric vehicle revolution

A research team led by Lynden Archer, professor and dean of Cornell Engineering, has developed a lithium battery that can charge in as little as five minutes. This could help address anxiety associated with the charging time of electric vehicles (EVs) and increase their adoption.

In their bid to reduce emissions from transportation, countries worldwide are looking to electrify various modes of transport. Road-based transport such as cars, buses, and trucks have led this transformation, aiming to even ban the sale of fossil fuel-powered cars in the next decade.

With technological advances, the fastest commercial charger can charge up an EV in no less than 30 minutes. While this might be a major improvement over the eight-hour charge cycles of a typical home-based charger, it still needs to be improved for large-scale adoption of EVs. 

"If you can charge an EV battery in five minutes, you don't need to have a battery that's big enough for a 300-mile [480km] range," said Archer in a press release. "You can settle for less, which could reduce the cost of EVs, enabling wider adoption."

Change in approach

Archer's team has previously worked on the charging problem of lithium-ion batteries. However, the team's approach has focused on the movement of ions in electrolytes and their crystallisation at metal anodes. The team used its expertise in these processes to make safer anodes that offer long-term storage. 

To devise a faster-charging battery, the team took a new approach by focusing on the kinetics of the electrochemical reactions. They looked keenly at a concept called the Damköhler number, which measures the reaction rate and the rate at which material is transported to a reaction site.

The team specifically looked for materials with low Damköhler numbers, which have fast transport rates, and found that a soft metal named indium could be used. 

Batteries that charge in five minutes

Indium is commercially used as a low-temperature solder to make indium tin oxide, a coating material for solar panels and touch screens. The researchers found that the metal has a very low migration energy barrier, which can help set the ion diffusion rate. It also has a good exchange current density, which is the reduction rate of ions at the anode. A combination of both these factors results in fast charging and long-duration storage.

"The key innovation is we've discovered a design principle that allows metal ions at a battery anode to freely move around, find the right configuration and only then participate in the charge storage reaction," said Archer.

"The end result is that in every charging cycle, the electrode is in a stable morphological state. It is precisely what gives our new fast-charging batteries the ability to repeatedly charge and discharge over thousands of cycles." 

The researcher suggests that combining the technology with induction-based wireless chargers can help reduce the size of the battery packs needed on vehicles, thereby reducing costs as well.

There is also an obstacle to overcome, though. Indium is very heavy and may not be suitable for making battery packs. The team is now working on discovering other lightweight materials that could perform the same role as indium.

The research was published in the journal Joule recently.

Rapid progress: Engineers develop breakthrough EV battery that charges in less than five minutes

Sony Honda Mobility (SHM), a joint venture between two Japanese technology giants, Sony and Honda, unveiled their electric vehicle brand Afeela at CES 2023. This year, at a media event, SHM drove the EV onto the stage using nothing but a PS5 controller.  

Over the past few years, multiple vehicle manufacturers have turned from fossil fuel cars to electric ones. While the focus for these manufacturers has remained on delivering maximum power and range for these vehicles, Japanese companies Sony and Honda are looking at this transition as an opportunity to transform mobility. 

Established in September 2022, their joint venture SHM aims to work with the two companies' strengths in the technology and mobility domains and establish itself as a 'Mobility Tech company'. Cars from the SHM stable are branded Afeela, and a prototype of the vehicle was operated using the controller at the ongoing CES 2024.  

 

What do we know about Afeela? 

The vehicle prototype unveiled in January last year is a four-door sedan that has evolved from Sony's Vision S, which was unveiled a few years prior. Much like other electric vehicles these days, the Afeela prototype also has scores of sensors and cameras to help the car gauge its surroundings and use this information to assist the driver. 

SHM does not intend to make its EV fully autonomous anytime soon but believes that the mobility intelligence will accompany manual vehicle control. It calls the onboard AI Vision Transformer and claims it achieves Level 2/2+ driving assistance under various driving conditions.  

The vehicle's interiors are designed to minimise distractions while driving and provide an environment where one can spend quality time entertained while inside the car. Passengers can watch content, play games, or listen to music inside the Afeela instead of waiting to arrive at the destination. 

Updates at CES 2024

In addition to driving the EV onto the stage, SHM also elaborated on the other updates that have taken place in the past year. The company's collaboration with Epic Games has gone beyond the portfolio of games that will be made available in the car and now extends to making an augmented reality (AR) map with the data gathered from the car's many sensors. 

SHM uses the powerful gaming engine Unreal Engine 5 to display stunning 3D maps of the car's surroundings to the car's occupants to improve safety. Eventually, this will broaden to include developing gaming and entertainment features. 

The company is also collaborating with Polyphony Digital to blur the differences between real and virtual in the car, much like the latter does in its Gran Turismo games.  

SHM has also agreed with Microsoft to use its Azure OpenAI Service to develop a conversational, personal agent for Afeela. 

In addition to collaborating with industry bigwigs, SHM is also opening up the developer space for Afeela for creators and developers to build applications and services that can run inside the futuristic EV. 

SHM plans to take preorders for the Afeela in 2025 and deliver its first EVs in the US in the spring of 2026. 

 

Sony lines up its new electric vehicle prototype on stage using a PS5 controller

Globally, there is a notable effort to transition the transportation sector to reduce emissions from internal combustion engine vehicles (ICEVs) and move towards electric vehicles (EVs). 

As evidence, more and more EVs are appearing on Irish roads every day. In the discussion about sustainable alternatives to ICE cars, there is no doubt that EVs stand out. 

They are a technologically more advanced and cleaner mode of transportation since they do not pollute the air (NB: various renewable sources can generate electricity to power the EVs; in Ireland, this is mainly electricity generated from wind (SEAI 2021). 

This reduces the greenhouse gases (GHGs) being released into the atmosphere as burning fossil fuels is a primary source of GHGs such as carbon dioxide (CO2), methane (CH4) and nitrous oxide (N2O) (Anandan, 2023). However, a new challenge emerges as Ireland and the rest of the world transition towards this cleaner transportation mode. What will happen to all the EV batteries when they reach the end of their lifecycle? 

According to the Irish Electric Vehicle Association (IEVA), by the second quarter of 2023, Ireland's roads had more than 100,000 electric cars, which included 58,000 battery electric vehicles (BEVs) and 47,000 plug-in hybrid electric vehicles (PHEVs) (IEVA 2023).

Additionally, the Sustainable Energy Authority of Ireland (SEAI) stated that for the first time in Ireland's motor history, sales of ICE vehicles were lower than EVs in the first quarter of 2023 (SEAI 2023a). 

The Central Statistics Office (CSO) has highlighted a continuous growth in the adoption of EVs on Irish roads. Its data shows that by August 2023, of all the newly registered cars in Ireland, 19% were BEVs. This is an increase from 13% over the same eight-month period in the previous year, 2022. 

More specifically, in the first eight months of 2022, there were 11,618 BEV registrations, which jumped to 19,021 in the same period of 2023 – a significant growth of 64% (CSO 2023). 

The graph below (see Figure 1) demonstrates the distribution of new BEVs from March to August 2023. The collected data clearly shows that BEVs accounted for 19.9% of all newly registered cars in August alone. NBan increase in June can be attributed to an SEAI grant reduction from €5,000 to €3,500 (SEAI 2023b). Nevertheless, some EV manufacturers, like Tesla, have opted to cover the €1,500 difference, ensuring their new customers still benefit from the total grant (Tesla 2023).  

Figure 1: Distribution of the new cars' fuel types registered between March and August 2023 (CSO 2023). 

The statistics for total registered cars between 2017-2022 demonstrate a clear upward trend in the number of BEVs from 1% to 15%. In contrast, diesel cars experienced a significant drop during the same time frame, a decline from 54% to 27% (exactly half – see Figures 2 and 3).

Figure 2: The percentage of new cars in Ireland by fuel type between 2017 and 2022 (CSO 2023). 

Figure 3: Number and Percentage of the new BEVs in Ireland between 2017 and 2022 (CSO 2023).

Challenges

A concern arises when considering the average lifespan of an EV battery. Typically ranging between 10 to 14 years, depending on the battery chemistry, many early EV adopters will soon face battery replacement. Due to constant charge and discharge cycles, a battery's state of charge (SoC) eventually degrades over time. 

Unfortunately, this degradation will result in a reduced charging capacity and, consequently, the vehicle's driving range (SEAI 2023c). This situation creates the primary environmental concern. 

Expired batteries generate a risk to the environment, particularly damaged lithium batteries, which are extremely hazardous and demand careful handling and disposal. 

Currently, EVs mostly use three types of batteries: lithium-iron-phosphate (LFP), nickel-manganese-cobalt (NMC) and nickel-cobalt-aluminium (NCA) (see Table 1). These batteries contain potentially dangerous chemicals such as lithium (Li), nickel (Ni) and cobalt (Co), increasing the magnitude of the disposal challenge (Man 2023).

Table 1: Different EV battery chemistries and attributes (Man 2023).

This creates a fundamental question: how are various types of batteries recycled (including expired, faulty and damaged ones)? According to Waste Electrical and Electronic Equipment (WEEE) Ireland, the organisation sends a specially trained team equipped with the necessary Personal Protective Equipment (PPE) and tools to safely handle, store and transport these battery packs for recycling (WEEE Ireland 2023). 

They are collaborating with contractors like ELV Environmental Services CLG (ELVES), who are fully permitted to collect such units for decommissioning.  Given the rigorous regulations, transporting certain batteries, such as damaged lithium ones, is quite challenging.  

All contractors are bound by the Carriage of Dangerous Goods by Road Regulations (ADR); these regulations require specific packaging measures in place.

Depending on the battery's condition, special containers might be needed. For example, when dealing with damaged EV lithium batteries, a specialised storage container such as the LiBa®Box is used – see Figure 4 (NB: this example costs more than €14,000) (Gelkoh 2023.)

Figure 4: Different LiBa®Box sizes (Gelkoh 2023).

However, there is an important point to consider. These batteries are not transported to the Irish recycling facilities but to Europe. In a correspondence to WEEE Ireland (Oct 2023), the head of batteries and projects informed that these batteries are sent to Accurec Recycling GmbH in Germany (Accurec 2023). 

This is done by K Metals Recycling (KMK 2023). KMK adheres to the TFS (trans-frontier shipment) regulations to manage this process and ensures a DGSA (dangerous goods safety adviser) is involved. Furthermore, the International Maritime Dangerous Goods Act (IMDG) supervises the final shipment to European processing plants. Directing this complicated and highly regulated process is quite challenging on its own. 

Future goals

This situation creates an opportunity for Ireland. On the one hand, decommissioning batteries present environmental risks, but on the other hand, there is an economic prospect associated with these batteries. 

The economic opportunity is in recovering and reusing the materials contained within these EV batteries. Ireland could capitalise on this by recycling batteries and repurposing their components in other applications, such as second life batteries (SLB). 

As presented in Haram et al (2021), once EV batteries reach around three-quarters of their nominal capacity (~70-80%), it is considered to have ended its primary life. Even the batteries with a lower state of health (SOH) still possess value depending on their condition

They can be adapted for secondary applications, such as supporting power in grid-scale photovoltaic (PV) plants or residential properties. The challenge is that repurposing them requires some upgrades and modifications, as most industry systems work at voltages between 800–1000 V. Figure 5 presents SLB applications, comparing the recycled industry with the EV battery system requirements. 

Figure 5: SLB applications/EV battery system requirements (Haram et al 2021). 

The EV batteries mentioned above, such as LFP, NMC or NCA, are made up of various components, each presenting distinct recycling challenges and requirements. 

While some of these components can be recycled with current technologies, others require more complicated and demanding procedures to recover the desired materials.  

As highlighted by Crownhart (2023), recycling facilities can recover more than 80% of lithium and almost all nickel and cobalt from decommissioned batteries.

Additionally, some aluminium (Al), graphite (Gr) and copper (Cu) can be extracted. NB: the recycling facilities can market these recycled materials at almost the same prices as the mined resources. 

For example, in (Leal et al 2023), the components of the lithium-ion batteries (LIB) consist of the aluminium current collector, usually a lithium compound such as lithium-cobalt oxide (LiCoO2) for cathode and the copper current collector and graphite serving as the anode (see Figure 6). 

Figure 6: Components of the lithium-ion batteries (LIB) (Leal et al. 2023). Cathode (+); Separator; Anode (-).

Figure 7 illustrates a detailed recycling process for LIB. Accurec Recycling GmbH executes this process in Germany, the destination for decommissioned Irish batteries (Accurec 2023).

Figure 7: Recycling of LIB (Accurec 2023). 

The Circular Energy Storage (CES) forecasts that the market for LIBs will keep growing and by 2030 (see Figure 8), it is estimated that 77% of the total LIBs installed volume will come from the EVs (Leal et al 2023).

Figure 8. Accumulative SLB volume (Haram et al 2021). 

Along with the advancements in battery technologies for BEVs, recycling methods must also evolve. Developing environmentally friendly processes that allow recycled materials to be repurposed efficiently with technical applications is essential. Implementing an ecofriendly approach is necessary in a circular economic model that promotes sustainable economic growth (see Figure 9) (Leal et al 2023).

Figure 9. LIBs Circular Economy (Leal et al 2023). 

Call to action

The main concern is that once an EV battery ends its lifecycle and is decommissioned, it is shipped to a recycling plant in Germany. Though this might seem like an attractive option, it is effectively a short-term solution. 

First, transporting used or damaged batteries presents an environmental risk; there is the constant threat that toxic elements from the batteries, such as cobalt or lithium, could contaminate the water or soil (NB: the transportation process itself by road and sea adds a carbon footprint.)

Second, Ireland is letting go of valuable recyclable materials that could be repurposed for domestic industries. This challenge could become an opportunity where the EV batteries are recycled here, not sending the problem away.  

As presented by Corrigan (2023), Ireland’s engineering Research and Development (R&D) ecosystem is remarkably strong and backed by organisations such as Enterprise Ireland, Science Foundation (SFI) Ireland, Industrial Development Agency (IDA) Ireland and Irish universities. 

Furthermore, enhanced with a pool of ambitious and highly educated engineers, Ireland could set up its own recycling facilities. By promoting and investing in R&D, developing partnerships with industry investors, academic organisations and government (ie, industry-academia-government collaborations), Ireland could establish facilities tailored for the Irish and later European markets. 

This would lead to the beginning of a new industrial sector, creating jobs and ensuring environmental protection. Several prospects include the utilisation of SLBs for less intensive applications, such as grid storage, energy storage for renewable energy systems or backup power sources (Haram et al 2021).

Using these batteries in secondary applications can extend their lifespan, therefore maximising their effectiveness and delaying their disposal phase and, in a situation of completely degraded SLBs, extracting and reprocessing valuable materials. Moreover, this entire effort would drive R&D in creating more sustainable EV battery technologies.

In order to be successful, this challenge requires a multi-layered approach. First, it is vital to educate EV owners about correct battery disposal practices and offer incentives to return their used battery packs for recycling (the general public must also be aware of these opportunities).

Second, it is necessary to implement robust regulations ensuring that every stakeholder, from manufacturers to final users, plays their part responsibly. 

Last, establishing international partnerships and collaborations. While Ireland is well able to develop its own SLB applications and establish a recycling infrastructure, it could also benefit significantly from global cooperative projects, public research and best practices from around the world.

In conclusion, while promising a sustainable and greener future, the EV revolution also introduces the task of managing and recycling decommissioned EV batteries. 

Ireland certainly has the resources to take proactive steps by recognising the potential risk of the used batteries and turning this into a significant opportunity (ie, an environmental challenge transformed into an industrial prospect). It is an opportunity to protect Ireland’s environment and drive economic, innovative and sustainable growth. 

Author: Adrian Szlapka, a professional with a decade of experience in the medtech industry, is a QA specialist at Abbott Diagnostic, Co Longford. He is in the final year of a Science and Technology Studies degree at the University of Galway. 

References

Journals articles/books

Haram, M.H.S.M., Lee, J.W., Ramasamy, G., Ngu, E.E., Thiagarajah, S.P. and Lee, Y.H. (2021) ‘Feasibility of utilising second life EV batteries: Applications, lifespan, economics, environmental impact, assessment, and challenges’, Alexandria Engineering Journal60(5), pp.4517-4536, available: https://www.sciencedirect.com/science/article/pii/S1110016821001757 [accessed 1 Oct 23].

Leal, V.M., Ribeiro, J.S., Coelho, E.L.D. and Freitas, M.B.J.G. (2023) ‘Recycling of spent lithium-ion batteries as a sustainable solution to obtain raw materials for different applications’. Journal of Energy Chemistry79, pp.118-134, available: https://www.researchgate.net/profile/Eld-Coelho/publication/362627937_Review_Recycling_of_spent_lithium-ion_batteries_as_a_sustainable_solution_to_obtain_raw_materials_for_different_applications/links/64355740609c170a130ce3c5/Review-Recycling-of-spent-lithium-ion-batteries-as-a-sustainable-solution-to-obtain-raw-materials-for-different-applications.pdf [accessed 17 Oct 23].

Internet sources

Accurec (2023) Accurec Battery Recycling, Accurec-Recycling GmbH, available: https://accurec.de/?lang=en [accessed 17 Oct 23].

Anandan, V. (2023) The Effects of Internal Combustion Engines on the Environment, Delta-Q Technologies, available: https://delta-q.com/industry-news/the-effects-of-internal-combustion-engines-on-the-environment/ [accessed 16 Oct 23].

Corrigan, E. (2023) Researching and developing Ireland’s engineering ecosystem: Supporting Ireland’s R&D ecosystem is crucial to maintain a competitive edge, The Irish Times, available: https://www.irishtimes.com/special-reports/2023/05/26/researching-and-developing-irelands-engineering-ecosystem/ [accessed 18 Oct 23].

Crownhart, C. (2023) Battery recycling: 10 Breakthrough Technologies 2023, MIT Technology Review, available: https://www.technologyreview.com/2023/01/09/1064886/battery-recycling-10-breakthrough-technologies-2023/ [accessed 17 Oct 23].

CSO (2023) Vehicles licensed for the first time August 2023, Central Statistics Office, available: https://www.cso.ie/en/releasesandpublications/ep/p-vlftm/vehicleslicensedforthefirsttimeaugust2023/ [accessed 12 Oct 23].

ELVES (2023) About ELVES, End-of-Life Vehicles Environmental Services CLG, available: https://www.elves.ie/en/about-elves [accessed 17 Oct 23].

Enterprise Ireland (2023) Funding Supports, Enterprise Ireland, available: https://www.enterprise-ireland.com/en/ [accessed 18 Oct 23].

Gelkoh (2023) LiBa®Box, Approval for the transport of critical lithium batteries( LP906/ADR ), wpml.org, available: https://www.kmk.ie/home [accessed 17 Oct 23].

IDA Ireland (2023) A Smooth, Fast and Successful Set-up for Your Operations in Europe, Industrial Development Agency Ireland, available: https://www.idaireland.com/ [accessed 18 Oct 23].

IEVA (2023) 58000 BEVs registered on Irish Roads, Irish Electric Vehicle Association, available: https://www.irishevassociation.ie/#:~:text=As%20of%20mid%20year%202023,you're%20in%20good%20company [accessed 12 Oct 23].

KMK (2023) Electrical, electronics & metals waste management solutions, KMK Metals Recycling Ltd., available: https://www.kmk.ie/home [accessed 17 Oct 23].

Man, H. (2023) What are LFP, NMC, NCA Batteries in Electric Cars?, Zecar, available: https://zecar.com/resources/what-are-lfp-nmc-nca-batteries-in-electric-cars [accessed 17 Oct 23].

SEAI (2021) Renewables, Sustainable Energy Authority of Ireland, Rialtas na hEirann (Government of Ireland), available: https://www.seai.ie/data-and-insights/seai-statistics/key-statistics/renewables/#comp00005c6fef2300000035f11bda accessed 19 Oct 23].

SEAI (2023a) Direction of Travel - the growing EV markets in Ireland, Sustainable Energy Authority of Ireland, Rialtas na hEirann (Government of Ireland), available:    https://www.seai.ie/blog/ev-direction-of-travel/#:~:text=In%202022%2C%20one%20in%20five,sink%20in%20for%20a%20moment[accessed 12 Oct 23].

SEAI (2023a) Understanding EV Battery Life, Sustainable Energy Authority of Ireland, Rialtas na hEirann (Government of Ireland), available: https://www.seai.ie/blog/understanding-ev-battery/#:~:text=Some%20Consumer%20Reports%20in%20the,is%2010%2D14%20years)!    [accessed 16 Oct 23].

SEAI (2023b) Electric Vehicle Grant Values, Sustainable Energy Authority of Ireland, Rialtas na hEirann (Government of Ireland), available: https://www.seai.ie/grants/electric-vehicle-grants/grant-amounts/ [accessed 16 Oct 23].

SFI (2023) Shaping Our Future: Delivering Today Preparing for Tomorrow – Science Foundation Ireland Strategy 2025, Science Foundation Ireland, available: https://www.sfi.ie/ [accessed 18 Oct 23].

Tesla (2023) Design Studio, Tesla Ireland, available: https://www.tesla.com/en_ie/model3/design#overview [accessed 16 Oct 23].

WEEE Ireland (2023) Guidance for Long Life Lithium Batteries & Electric Vehicle Batteries, Waste Electrical and Electronic Equipment Ireland, available: https://www.weeeireland.ie/guidance-for-lll-ev-batteries/ [accessed 17 Oct 23].

Infographics

Accurec (2023) Recycling of LIB, [image], available: https://accurec.de/?lang=en [accessed 17 Oct 23].

CSO (2023) Distribution of the new cars fuel types registered between March and August 2023, [image], available: https://www.cso.ie/en/releasesandpublications/ep/p-vlftm/vehicleslicensedforthefirsttimeaugust2023/ [accessed 12 Oct 23].

CSO (2023) Number and Percentage of the new BEVs in Ireland between 2017 and 2022, [image], available: https://www.cso.ie/en/releasesandpublications/ep/p-vlftm/vehicleslicensedforthefirsttimeaugust2023/ [accessed 12 Oct 23].

CSO (2023) The percentage of new cars in Ireland by fuel type between 2017 and 2022, [image], available:  https://www.cso.ie/en/releasesandpublications/ep/p-vlftm/vehicleslicensedforthefirsttimeaugust2023/ [accessed 12 Oct 23].

Gelkoh (2023) Different LiBa®Box sizes, [image], available: https://www.kmk.ie/home [accessed 17 Oct 23].

Haram, M.H.S.M., Lee, J.W., Ramasamy, G., Ngu, E.E., Thiagarajah, S.P. and Lee, Y.H. (2021) Accumulative SLB volume’ [image], available: https://www.sciencedirect.com/science/article/pii/S1110016821001757 [accessed 18 Oct 23].

Haram, M.H.S.M., Lee, J.W., Ramasamy, G., Ngu, E.E., Thiagarajah, S.P. and Lee, Y.H. (2021) SLB applications / EV battery system requirements’ [image], available: https://www.sciencedirect.com/science/article/pii/S1110016821001757 [accessed 18 Oct 23].

Leal, V.M., Ribeiro, J.S., Coelho, E.L.D. and Freitas, M.B.J.G. (2023)‘Components of the lithium-ion batteries (LIB)’[image], available: https://www.researchgate.net/profile/Eld-Coelho/publication/362627937_Review_Recycling_of_spent_lithium-ion_batteries_as_a_sustainable_solution_to_obtain_raw_materials_for_different_applications/links/64355740609c170a130ce3c5/Review-Recycling-of-spent-lithium-ion-batteries-as-a-sustainable-solution-to-obtain-raw-materials-for-different-applications.pdf [accessed 17 Oct 23].

Leal, V.M., Ribeiro, J.S., Coelho, E.L.D. and Freitas, M.B.J.G. (2023) LIBs Circular Economy’ [image], available: https://www.researchgate.net/profile/Eld-Coelho/publication/362627937_Review_Recycling_of_spent_lithium-ion_batteries_as_a_sustainable_solution_to_obtain_raw_materials_for_different_applications/links/64355740609c170a130ce3c5/Review-Recycling-of-spent-lithium-ion-batteries-as-a-sustainable-solution-to-obtain-raw-materials-for-different-applications.pdf [accessed 17 Oct 23].

Tables

Man, H. (2023) ‘Different EV battery chemistries and attributes’, [table], available:  https://zecar.com/resources/what-are-lfp-nmc-nca-batteries-in-electric-cars [accessed 17 Oct 23].

Decommissioned electric vehicle batteries: Ireland's challenge and opportunity

A technology firm focused on industry, infrastructure, transport, and healthcare – Siemens not only announced a partnership with Sony but also unveiled other collaborations to devise the latest innovations in immersive engineering.

The two renowned companies collaborated on their systems – Siemens Xcelerator portfolio of industry software and Sony’s new mixed reality headset – a novel spatial content creation system to form Siemens’ NX immersive Designer, according to a statement by Siemens. 

This new system exhibits a myriad of features including an XR head-mounted display with high-quality 4K OLED Microdisplays and controllers for intuitive interaction with 3D objects. 

Launching later in 2024

“Enabling designers and engineers to create and explore design concepts in a borderless immersive workspace, the new solution will kickstart content creation for the industrial metaverse,” the company stated. 

Siemens’ NX immersive Designer aiming to launch later this year.

Furthermore, Siemens also collaborated with Amazon Web Services to create generative AI more accessible to application developers.

The Siemens Xcelerator open business platform aims to integrate the tangible and virtual realms, enabling digital transformation across various industries.

Dr Roland Busch–Siemens CEO will showcase technology that is enabling leading brands to improve the way we live, work, move, and make.

“At Sony, we are passionate about empowering creators with cutting-edge technologies, and in the field of spatial content creation, we have thrived in innovating the way they work by utilising our proprietary motion and display technologies,” said Yoshinori Matsumoto, executive deputy president and officer in charge of technology and incubation, Sony Corporation. 

“By combining our technologies and Siemens’ expertise in engineering, we are excited to enable more immersive engineering that redefines the daily workflow of designers and engineers. The high-quality, realistic rendering and intuitive interaction will give creators tools to pursue more immersive creative processes that fuel further innovation in the industrial metaverse.”

The unveiling took place at CES 2024, one of the world’s largest tech events in early January.

The company's goal is to revolutionise industries and daily life by stimulating the industrial metaverse, accelerating innovation, improving sustainability, and embracing novel technologies.

Introducing Inhab

Dr Roland Busch, CEO of Siemens, emphasised sustainability in innovation at the CES keynote speech and said: “It’s a place where you combine the real and digital world. A place for industrial innovations.

“Simulate whatever you want in the digital world before you build it in the real world. Build products using fewer resources and that can be recycled.”

According to Siemens’ official statement, they firm introduced the Inhab™ smart home energy management portfolio at CES. 

Inhab is a set of habitat solutions that empower users with complete visibility and command over energy sources and their distribution within the home. 

It includes features like real-time alerts, continuous 24/7 monitoring, and customisable energy goal settings, offering occupants the transparency required for informed decision-making. 

The company noted that as the trend toward electric appliances, EV charging, and solar arrays in homes grows, these precise monitoring and management solutions will play a crucial role in reducing energy consumption and utility bills while simultaneously enhancing safety and capacity.

This information highlights Siemens' endeavours to merge the physical and digital worlds, fostering innovation and accessibility through partnerships and technological advancements.

Siemens teams up with Sony as they unveil spatial headset to enable 'industrial metaverse'

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