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Coreshell EV Batteries: MG-Si-gnificantly Better Than Tesla?


Startup Coreshell Technologies has outpaced Tesla’s efforts to integrate metallurgical silicon into electric battery anodes.


January 21, 2025 by Austin Futrell at EE Power


The electric vehicle industry’s reliance on graphite for battery anodes faces several challenges, from high costs to China’s near monopoly on graphite processing. This dependency creates supply chain vulnerabilities and drives up production expenses. As the EV industry seeks alternatives, addressing these issues has become a concern for achieving mass-market EV adoption.


Coreshell Technologies has released a potential solution with its commercial-scale 60 Ah battery cells featuring anodes made from 100% domestically sourced metallurgical silicon (MG-Si). This development offers cost-effectiveness, scalability, and environmental benefits, potentially creating a pathway for a more affordable and sustainable EV battery, giving Coreshell Technologies an advantage over Tesla.

 

Coreshell Technologies vs. Tesla

Coreshell Technologies has achieved what many legacy battery companies have only aspired to with the development of their 60 Ah EV battery. This innovation is particularly noteworthy considering Tesla's ambitions. In 2020, Elon Musk announced Tesla's plans to incorporate metallurgical silicon into their EV batteries, recognizing its potential to revolutionize the industry. However, despite Tesla's significant resources, the electric vehicle maker has not succeeded. Coreshell has managed to beat them to the punch.


Tesla has been working on implementing dry coating technology for electrodes to reduce manufacturing costs and time. However, It has faced challenges, such as achieving precise coating thickness and managing heat generation during scaling. While Tesla continues to push the boundaries of battery technology, Coreshell's development of metallurgical silicon anodes positions it as a competitor in the rapidly evolving EV battery market.

 

What is Metallurgical Silicon?

Metallurgical silicon (MG-Si) is a form of silicon primarily used to produce aluminum alloys, solar panels, and EV batteries. It is derived from quartz and heated with carbon in an electric arc furnace. The result is high-purity silicon that can be refined or used directly in various industrial applications.


In EV batteries, MG-Si is used instead of graphite as an anode material. MG-Si has a 10x higher energy capacity than graphite, meaning it can contain more energy per unit of weight, improving battery performance. However, it has traditionally been less favorable due to issues with expansion during charge/discharge cycles. This leads companies such as Coreshell to develop innovative techniques to mitigate these challenges and make MG-Si a viable alternative for battery technology.

 

Pricing and Environmental Benefits

Although traditional synthetic silicon is engineered to reduce swelling, it remains prohibitively expensive, leading to cost concerns. MG-Si is sourced from abundant domestic materials, resulting in a cost savings of 50% per kg. These cost savings could dramatically reduce EVs, making them more accessible.


Environmental sustainability is another critical advantage. Coreshell batteries lower carbon emissions by 29% compared to traditional graphite-anode lithium-ion phosphate battery cells. Life cycle assessments highlight a 16% reduction in emissions relative to nickel manganese cobalt/graphite batteries.


Benoist Ollivier, Ferroglobe’s Chief Technology and Innovation Officer, stated in a press release: “After testing their technology, coupled with our high-purity products, we believe Coreshell offers the most viable pathway to mass-market EV adoption, leveraging the high energy density of silicon-dominant anodes to reduce costs, lower CO2 footprints, and accelerate the industry’s transition to clean energy.”

 

Market Readiness

As Coreshell progresses toward commercializing its 60 Ah battery cells, the company is making strides in scaling its production capabilities. A newly built 4 MWh manufacturing facility in San Leandro, California, is already operational. Coreshell plans to expand its footprint further with plans for a 100 MWh facility. This new site, currently in the design phase, will boost Coreshell's ability to supply its battery technology to the market. In 2025, the company will begin delivering samples of its 60 Ah battery cells to global automakers.

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