An array of new projects seeks to catalyze the lithium supply chain and keep pace with rising demand driven by the energy transition.
At the heart of energy transition is a powerful force for the future: lithium. This lightweight element is a lynchpin in the quest for electrifying a more sustainable world. Lithium batteries are increasingly used to harness renewable energy, power the cars we drive, and “fuel” the high-tech digital gadgets ubiquitous in our daily lives.
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A bulldozer begins the first earthwork at the site of future permanent facilities at the Thacker Pass Lithium Mine on June 19, 2023.
The journey from ore to energy can be traced through many steps representing many industrial sectors. There is innovation and transformation along every step of the way.
Experts at Bechtel are committed to this journey, helping design and build important projects that will realize an electrified and sustainable future through lithium.
The Battery Value Chain
“For batteries, everything starts with mining” said Vivek Sista, PhD, battery technical manager at Bechtel. “Both of the most used chemistries of batteries require lithium. Handheld devices, smartphones, power tools, electric vehicles, and grid-scale storage are not possible without the raw material.”
The lithium journey starts with mining the raw ma¬terial and, ideally, ends with recycling and repurposing used batteries. Along the way it is refined, converted into “active” materials in batteries (anodes, cathodes, and electrolytes), turned into cells, and then put into battery packs for use in various devices.
Engineers and construction professionals at Bechtel are designing and building mining, processing, and manufacturing projects that enable each step in this “battery value chain.” Bechtel brings deep expertise in managing capital projects with significant chemical processes—projects that have increased access to energy and enhanced economies around the world. Now, there is a focus on taking that experience directly to projects that make the world a cleaner and more sustainable place.
Mining & Processing
“As we move to energy sources that are mineral and metal rich, it all starts with the extraction,” says Rich Waller, business development manager at Bechtel.
Principally, a mine comprises five areas: the mine, infrastructure, the processing and materials-handling facilities, and the tailings and waste facilities. Bechtel designs and builds the processing and infrastructure facilities, which often account for the bulk of the engineering complexity and the capital required.
“The mining industry is dealing with complex execution, complex supply chains, and multiple stakeholders such as downstream customers, government, and the teams who build the facilities, which is where we bring value to our customers looking to unlock this critical resource,” said Waller.
Experts foresee the need for more mining projects, expanding capability as the world continues to move to net zero carbon emissions. The International Energy Agency estimates that global demand for lithium will grow tenfold by 2050.
“The future I envision is rather than using consumable fossil fuels for the predominate energy output, we need energy sources comprised of minerals that are not consumed, and can be recycled and reused,” says Waller.
Battery Manufacturing
After mining and processing, lithium is ready to be turned into batteries.
“Processed lithium becomes a pivotal component in crafting ‘active materials’—the heart of batteries where the electricity generation happens,” explained Sista. “These materials are meticulously assembled into cells, which are eventually integrated into expansive battery packs.”
One electric vehicle battery, for example, can contain as many as thousands of individual cells. Bechtel has comprehensive involvement in different aspects of battery manufacturing —from cathodes to anodes, from electrolytes to the packaged batteries and their charging ecosystems. These facilities are complex, first-of-their-kind manufacturing plants that require Bechtel’s experience with building industrial plants at scale.
Electric Vehicles & Charging
Batteries are not just for electric vehicles, but they are the largest destination for lithium batteries. According to the International Energy Agency, EVs are expected to account for one in five cars sold worldwide in 2024.
More electric vehicles mean fewer greenhouse gas emissions. But an electric vehicle future requires a massive built-out of charging infrastructure. Bechtel is working with a variety of customers to design and build charging infrastructure. In one case, Bechtel is working to deploy more electric school buses.
Recycling
Lithium batteries nearing the end of their life may not hold enough charge for applications like electric vehicles, but they could be repurposed for energy grid storage.
Eventually, batteries reach the end of their useful life. Experts see recycling as an important conclusion of the life of lithium.
“I expect to see more recycling projects come online that will sustain the supply chain of lithium,” says Sista.
Sustainability
Sustainability is a big focus for the mining sector and the advanced manufacturing facilities needed to produce and recycle batteries.
“A key part of planning has to be focused on how host communities will benefit from the mine both in the short and long term,” says Waller. “We always look to bring a positive impact with lasting opportunity for jobs, economic activity, upskilling, and enabling local businesses to grow beyond the mine.”
Looking globally, Bechtel is doing its part and is helping customers work toward achieving net zero emissions by 2050.
Lithium plays a big part.
“The lithium battery’s lifespan is extending, and with the proliferation of renewable energy sources like solar, hydro, and wind, we’re moving towards a world that can be powered sustainably and efficiently by many methods.,” says Sista. “The cost of batteries is decreasing, signaling a promising direction for EVs and energy storage. Lithium-ion technology will remain a cornerstone for the next 15 years and beyond.”