The Role of Gigafactories in Reducing CO2 Emissions
By Sandrine Cheminaud, Director of Development for the Process Industries Division
For several years now, the Hauts-de-France region has been transforming into the “Battery Valley.” Indeed, massive factory projects are springing up there to manufacture the future batteries for our “made in France” electric vehicles. France aims to produce 2 million electric vehicles by 2030 to reduce its CO2 emissions. Europe, as a major car manufacturer, has mandated the phase-out of internal combustion engine vehicles starting in 2035.
Given that the cost of the battery accounts for 40% of a vehicle's price, what does this mean for the European automotive industry?
Indeed, if Europe misses the opportunity to manufacture batteries in European gigafactories, automakers are going to face some very serious problems.
Why are these plants called gigafactories?
They’re called gigafactories because of their large size, which is necessary to achieve profitability. The term “gigafactories” was coined by Elon Musk.
Gigafactories are part of the effort to build a carbon-free future. And a cutting-edge industry inevitably requires expert and agile partners. Can you tell us about the first projects in Europe?
In Europe, a Scandinavian startup launched the first battery factory project in 2018. We traveled to Sweden to meet with them and explain that we could support them in certain areas thanks to our expertise in chemistry, cleanrooms, and dry rooms. Curiosity is essential in these new fields and processes, which we still know very little about. We asked them: “Can you explain to us how to manufacture a battery?” For two hours, they told us everything. They explained that at the end of the battery manufacturing process, a toxic and flammable solvent called an electrolyte must be injected, which requires specific manufacturing techniques. They told us that only the Americans had mastered this process.
We replied: “We know how to do it, too.”
That’s how it all began. We built the solution together and earned their trust. Then, in a second phase, they consulted us on the major project of the gigafactory for clean and dry rooms. It’s a very large project that we won because we had convinced them on the first project and earned their trust.
As Director of Market Development, you’re working on some of the most ambitious electric battery plant projects in France. Can you tell us about the gigafactory projects in France?
In France, there are currently 3 to 4 gigafactory projects on the market. Our experience and expertise have allowed us to attract the interest of all stakeholders. Since the industry is still in its early stages, we must be extremely agile and constantly offer tailored solutions. We know how to find resources wherever they are—that’s our strength—and we’re able to respond very quickly to these issues.
What are the most important projects Equans is working on?
Among the most important projects is the ACC gigafactory in Billy-Berclau Douvrin, a project at the heart of the Fourth Industrial Revolution. ACC (Automotive Cells Company) is a startup founded by Saft (manufacturer of satellite batteries), Stellantis (the new entity comprising Citroën, Peugeot, and Fiat), and Mercedes. They decided to manufacture batteries in the Hauts-de-France region to be close to automakers and gain expertise in these fields.
Another major project is the Envision plant in Douai, which will produce the future batteries for Renault's electric vehicles. Can you tell us more about it?
Envision is an experienced company that has been in business for years and has already built gigafactories in Asia. It won the contract with Renault and is building its first gigafactory in France, in Douai, with 100% of the batteries to be sold to Renault.
How are electric vehicle batteries made?
The lithium used in batteries is extremely sensitive to water, which is why we build anhydrous rooms to prevent any moisture from coming into contact with the rare metals. This requires dry rooms with very low humidity levels. The metals used are then processed into powder and subsequently into two pastes: the cathode and the anode. These pastes are spread out and passed through very large furnaces, then stacked in several layers of cathodes and anodes. They are placed in cases, and electrolyte is injected into them. And there you have it—an electric battery.
The automotive industry is now embarking on its electric revolution to reduce the carbon footprint of our daily transportation. But another question is already arising: What should be done with the batteries once they reach the end of their useful life?
The future of electric vehicle batteries will only make sense if we know how to recycle them. There are many raw materials involved: lithium, manganese, and nickel. All of these resources could one day run out. Furthermore, there are massive battery manufacturing projects underway. Without a battery recycling program, it won’t work—the cycle won’t be closed.
The Swedish startup is currently building its plant to process used batteries. In France, battery manufacturers are working with chemists to develop recycling solutions. Initially, battery recycling will be used to recycle scrap generated during production—specifically, defective batteries that are tested during the manufacturing process. Manufacturers will subsequently optimize their production lines. And then, of course, batteries that have reached the end of their life will be recycled.
Manufacturers are considering the entire value chain for electric vehicle batteries. From metal sourcing to the recycling of end-of-life batteries.
