Elkem's role in driving electric mobility

Electrification is a key area in the automotive industry, and materials and components play a critical role of in this transition. Concerns over the availability and extraction of critical minerals as we work towards the goal of net-zero emissions underscore the importance of sustainable mobility solutions. In this context, Elkem emerges as a key player, specializing in solutions tailored for the electrification of mobility. Elkem is vertically integrated from quartz mining to silicon/ferrosilicon production to silicone manufacturing. With over 70 years of experience in automotive applications, we take pride in our agility to innovate into emerging markets to create a sustainable future.

Silicon

Silicon plays a crucial role in the development of batteries for the EV industry. One of the benefits of using silicon as an anode material in lithium-ion batteries is its higher energy density, which results in longer driving range. This is because silicon can accommodate more lithium than state-of-the-art graphite materials. Currently, Elkem and Polestar are collaborating to explore the possibility of producing silicon components with zero CO₂ footprint for use in climate-neutral cars. The project will begin by examining GHG emissions associated with silicon for batteries. This partnership represents an important step towards developing more sustainable and efficient batteries for the EV industry.

Furthermore, silicon is used in aluminium alloys to reinforce the structural integrity of lightweight vehicle designs, which is a key aspect of modern electric vehicle construction. As a critical alloying element, silicon enhances the strength, durability, and heat resistance of aluminium-based materials. When used in larger amounts, silicon also strongly reduces the melting temperature and increases the fluidity and castability of the aluminium alloy, which is essential for die casting operations. Adding silicon to aluminium is necessary for high-pressure die casting operations. Silicon also makes materials even lighter, as it has a lower solid density than aluminium. This makes parts more cost-effective and fuel-efficient. The synergy between silicon and aluminium is driving the transition towards more efficient, eco-friendly, and high-performance vehicles in the era of electrification.

Ferrosilicon

Premium quality ferrosilicon, such as Elkem ElekSil(r) FeSi, is needed in the production of electrical steel used in EV motors, transformer cores, and generators.

These electrical steel grades typically contain about 3 to 3.5% silicon. Silicon is the key alloying element in such steel as it decreases the electrical conductivity of steel. This main property makes it highly efficient for channelling magnetic flux in transformers, generators, and motors.

The surge in use is driven by the rapid growth in both EVs, charging station infrastructure, and renewable energy (windmills, hydropower). According to S&P Global, the global gross demand for xEV-grade electrical steel required for the manufacturing of traction motors in hybrid and electric light vehicles is expected to grow from 320,000 tons demanded in 2020 to just over 2.5 million tons by 2027 and more than 4.0 million tons by 2033. These new applications have driven much innovation in the sector, as customers and regulations demand greater performance from electrical devices.

Silicones

Automotive battery cables

Silicones is the material of choice to insulate and durably protect cables in hybrid and electric vehicles (H&EVs). EVs require an ever-increasing number of cables to ensure conductivity and manage temperature spikes due to a high throughput of electrical energy. The overriding advantage of silicone rubber as the insulation material of choice for battery cables is their unequalled ability, compared to all other insulation materials (PVC, polyethylene, etc.), to withstand huge temperature variations from -60C to +250°C. Elkem cable insulation materials are tested to remain stable at 200°C for 3,000 hours or 180°c for 3,000 hours (depending on the requirements). This means that they can adapt to the heat generated by traditional motors and can optimize the Thermal Management Systems (TMS) of EVs.

Flexibility is another key reason for using silicone rubber for battery cables. This is a major consideration for the entire automotive industry, both OEMs and parts makers, in designing and assembling their engines, which have increasingly complex wiring in very tight motor housings, often requiring U-shaped or hairpin curves to connect different engine parts. This flexibility is an important factor in reducing manufacturing processing time and improving efficiency.

Also, silicone insulation materials for automotive cables are very lightweight compared to other materials that meet high temperature, thus contributing to energy savings and improving the environmental impact for cars and particularly EVs. Additionally, silicone insulation materials provide the highest level of safety because of their fire-retardant properties and their unique capacity to self-extinguish, avoiding propagation when flames do ignite in the engine housing.

Thermal management and sealing of H&EV battery packs

As global production of H&EVs continues to increase, greater attention is being focused on optimizing the performance of the vehicle, and of the battery that powers it. One of the key factors that affects the performance of a battery is its temperature, with optimum battery power and longevity generally achieved between 15 °C and 35 °C.

Thermal management systems are crucial in maintaining temperatures across of the entire battery assembly within this range during charging and discharging, which reduces the risk of thermal runaway and prevents fire outbreaks. As H&EV technology becomes more widespread, and high-speed charging systems become more in demand, achieving these goals is set to become an even greater challenge. Silicones for thermal management from Elkem are available in foam, gel, and adhesive form to cater for every requirement for thermal insulation and heat dissipation in H&EV battery packs. Additionally, these products are inherently fire-retardant, giving them a clear advantage over other materials commonly used in the industry.

Battery sealing in H&EVs is essential to maintain battery integrity and to eliminate safety issues and maximize product lifetime. Battery performance and cost is widely recognized as a limiting factor in the uptake of H&EVs. This means that automotive manufacturers need to protect battery packs from the external environment to extend cycle life and reduce the risk of battery failure. Such protection is achieved by using carefully chosen materials to ensure a tight seal between the parts of the battery casing. The aim is to eliminate water ingress (and so avoid the risk of short-circuiting), as well as to avoid dust entering the battery casing and posing a fire hazard. At Elkem, we supply four main classes of silicone products for sealing and gasketing battery packs in H&EVs.

In summary, Elkem's comprehensive range of silicon, ferrosilicon, and silicone products play a fundamental role in advancing electric mobility. By addressing key challenges in battery technology, infrastructure development, and vehicle innovation, Elkem contributes significantly to the realization of a cleaner, more sustainable transportation ecosystem. As the world strives towards a net-zero future, Elkem's commitment to innovation and sustainability underscores its vital role in driving the electric mobility progress. Together with industry partners, Elkem paves the way towards a future where electric vehicles are not just a choice but a necessity for a greener planet.