The Extraordinary Raw Materials in a Tesla Model S
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Extraordinary Raw Materials in a Tesla Model S

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The Extraordinary Raw Materials in a Tesla Model S

Presented by: Red Cloud Klondike Strike (Equity crowdfunding in mining)

The Tesla Model S is the world’s most-wanted electric car, with 100,000 units already sold as of December 2015.

Critics have lauded the car for its impressive safety rating, range, and design. However, it is also worth considering that it is the incredible raw materials that go into the Tesla Model S that help to make all of these things possible.

Here’s what’s in a Tesla Model S:

Body and Chassis

Bauxite: The Tesla Model S body and chassis are built almost entirely from aluminum, which comes from bauxite ore. Aluminum is lightweight, which helps to maximize the range of the battery beyond that of other EVs. The total amount of aluminum used in the car is 410 lbs (190 kg).

Boron steel: High-strength boron steel is used to reinforce the aluminum at critical safety points. Boron steel is made from iron, boron, coking coal, and other additives.

Titanium: The underbody of the Tesla Model S is made from ultra high-strength titanium, which protects the battery from nearly any roadside force or piercing.

Interior

Rare Earth Metals: While Tesla engines and batteries do not use rare earths, most high-end car speakers and other electronics use rare earth elements such as neodymium magnets.

Plastic: Most plastics are made from petrochemicals.

Leather: Leather is derived from animal skin, mainly cowhides .

Silicon: Glass windows and other features are made from silicon.

Carbon fiber and copper wire are also used within the interior for various components.

Wheels

Bauxite: Aluminum alloy wheels are also made from bauxite ore.

Rubber: Natural rubber comes from rubber trees, but today 70% of US rubber is synthetic, made from petrochemicals.

Induction Engine:

Copper: Tesla’s high-performance copper rotor motor delivers 300 horsepower and weighs 100 lbs (45.4 kg).

Steel: The stationary piece of the engine, the stator, is made from both copper and steel.

Battery:

The Tesla battery pack weighs 1,200 lbs (540 kg), which is equal to about 26% of the car’s total weight. This puts the car’s center of gravity a mere 44.5 centimeters off the ground, giving the car unprecedented stability.

The battery itself contains 7,104 lithium-ion battery cells. Here’s what’s in each cell:

Cathode: The Tesla Model S battery cathode uses an NCA formulation with the approximate ratio: 80% nickel, 15% cobalt, and 5% aluminum. Small amounts of lithium are also used in the cathode.

Anode: The negative terminal uses natural or synthetic graphite to hold lithium ions. Small amounts of silicon are also likely used in the anode as well.

Electrolyte: The electrolyte is made of a lithium salt.

Copper and/or aluminum foil is also used in the battery as well.

Note: all numbers above are based on the 85 kWh battery model.

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Mining

The 50 Minerals Critical to U.S. Security

This graphic lists all minerals that are deemed critical to both the economic and national security of the United States.

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The 50 Minerals Critical to U.S. Security

This was originally posted on Elements. Sign up to the free mailing list to get beautiful visualizations on natural resource megatrends in your email every week.

The U.S. aims to cut its greenhouse gas emissions in half by 2030 as part of its commitment to tackling climate change, but might be lacking the critical minerals needed to achieve its goals.

The American green economy will rely on renewable sources of energy like wind and solar, along with the electrification of transportation. However, local production of the raw materials necessary to produce these technologies, including solar panels, wind turbines, and electric vehicles, is lacking. Understandably, this has raised concerns in Washington.

In this graphic, based on data from the U.S. Geological Survey, we list all of the minerals that the government has deemed critical to both the economic and national security of the United States.

What are Critical Minerals?

A critical mineral is defined as a non-fuel material considered vital for the economic well-being of the world’s major and emerging economies, whose supply may be at risk. This can be due to geological scarcity, geopolitical issues, trade policy, or other factors.

In 2018, the U.S. Department of the Interior released a list of 35 critical minerals. The new list, released in February 2022, contains 15 more commodities.

Much of the increase in the new list is the result of splitting the rare earth elements and platinum group elements into individual entries rather than including them as “mineral groups.” In addition, the 2022 list of critical minerals adds nickel and zinc to the list while removing helium, potash, rhenium, and strontium.

Mineral Example UsesNet Import Reliance
BerylliumAlloying agent in aerospace, defense industries 11%
AluminumPower lines, construction, electronics 13%
ZirconiumHigh-temparature ceramics production 25%
PalladiumCatalytic converters40%
GermaniumFiber optics, night vision applications50%
LithiumRechargeable batteries 50%
MagnesiumAlloys, electronics 50%
NickelStainless steel, rechargeable batteries 50%
TungstenWear-resistant metals50%
BariteHydrocarbon production75%
ChromiumStainless steel75%
TinCoatings, alloys for steel 75%
CobaltRechargeable batteries, superalloys76%
PlatinumCatalytic converters 79%
AntimonyLead-acid batteries, flame retardants 81%
ZincMetallurgy to produce galvanized steel 83%
TitaniumWhite pigment, metal alloys88%
BismuthMedical, atomic research 94%
TelluriumSolar cells, thermoelectric devices95%
VanadiumAlloying agent for iron and steel96%
ArsenicSemi-conductors, lumber preservatives, pesticides 100%
CeriumCatalytic converters, ceramics, glass, metallurgy100%
CesiumResearch, development100%
DysprosiumData storage devices, lasers100%
ErbiumFiber optics, optical amplifiers, lasers100%
EuropiumPhosphors, nuclear control rods 100%
FluorsparManufacture of aluminum, cement, steel, gasoline100%
GadoliniumMedical imaging, steelmaking100%
GalliumIntegrated circuits, LEDs100%
GraphiteLubricants, batteries100%
HolmiumPermanent magnets, nuclear control rods100%
IndiumLiquid crystal display screens 100%
LanthanumCatalysts, ceramics, glass, polishing compounds100%
LutetiumScintillators for medical imaging, cancer therapies 100%
ManganeseSteelmaking, batteries 100%
NeodymiumRubber catalysts, medical, industrial lasers 100%
NiobiumSteel, superalloys100%
PraseodymiumPermanent magnets, batteries, aerospace alloys100%
RubidiumResearch, development in electronics 100%
SamariumCancer treatment, absorber in nuclear reactors 100%
ScandiumAlloys, ceramics, fuel cells100%
TantalumElectronic components, superalloys100%
TerbiumPermanent magnets, fiber optics, lasers100%
ThuliumMetal alloys, lasers 100%
YtterbiumCatalysts, scintillometers, lasers, metallurgy 100%
YttriumCeramic, catalysts, lasers, metallurgy, phosphors 100%
IridiumCoating of anodes for electrochemical processesNo data available
RhodiumCatalytic converters, electrical componentsNo data available
RutheniumElectrical contacts, chip resistors in computersNo data available
HafniumNuclear control rods, alloysNet exporter

The challenge for the U.S. is that the local production of these raw materials is extremely limited.

For instance, in 2021 there was only one operating nickel mine in the country, the Eagle mine in Michigan. The facility ships its concentrates abroad for refining and is scheduled to close in 2025. Likewise, the country only hosted one lithium mine, the Silver Peak Mine in Nevada.

At the same time, most of the country’s supply of critical minerals depends on countries that have historically competed with America.

China’s Dominance in Minerals

Perhaps unsurprisingly, China is the single largest supply source of mineral commodities for the United States.

Cesium, a critical metal used in a wide range of manufacturing, is one example. There are only three pegmatite mines in the world that can produce cesium, and all were controlled by Chinese companies in 2021.

Furthermore, China refines nearly 90% of the world’s rare earths. Despite the name, these elements are abundant on the Earth’s crust and make up the majority of listed critical minerals. They are essential for a variety of products like EVs, advanced ceramics, computers, smartphones, wind turbines, monitors, and fiber optics.

After China, the next largest source of mineral commodities to the United States has been Canada, which provided the United States with 16 different elements in 2021.

The Rising Demand for Critical Minerals

As the world’s clean energy transitions gather pace, demand for critical minerals is expected to grow quickly.

According to the International Energy Association, the rise of low-carbon power generation is projected to triple mineral demand from this sector by 2040.

The shift to a sustainable economy is important, and consequently, securing the critical minerals necessary for it is just as vital.

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Energy

Visualizing China’s Dominance in Clean Energy Metals

Despite being the world’s biggest carbon emitter, China is also a key producer of most of the critical minerals for the green revolution.

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Visualizing China’s Dominance in Clean Energy Metals

This was originally posted on Elements. Sign up to the free mailing list to get beautiful visualizations on natural resource megatrends in your email every week.

Renewable sources of energy are expected to replace fossil fuels over the coming decades, and this large-scale transition will have a downstream effect on the demand of raw materials. More green energy means more wind turbines, solar panels, and batteries needed, and more clean energy metals necessary to build these technologies.

This visualization, based on data from the International Energy Agency (IEA), illustrates where the extraction and processing of key metals for the green revolution take place.

It shows that despite being the world’s biggest carbon polluter, China is also the largest producer of most of the world’s critical minerals for the green revolution.

Where Clean Energy Metals are Produced

China produces 60% of all rare earth elements used as components in high technology devices, including smartphones and computers.

The country also has a 13% share of the lithium production market, which is still dominated by Australia (52%) and Chile (22%). The highly reactive element is key to producing rechargeable batteries for mobile phones, laptops, and electric vehicles.

China's ShareExtractionProcessing
Copper 8%40%
Nickel 5%35%
Cobalt 1.5%65%
Rare Earths 60%87%
Lithium13%58%

But even more than extraction, China is the dominant economy when it comes to processing operations. The country’s share of refining is around 35% for nickel, 58% for lithium, 65% for cobalt, and 87% for rare earth elements.

Despite being the largest economy in the world, the U.S. does not appear among the largest producers of any of the metals listed. To shorten the gap, the Biden administration recently launched an executive order to review the American strategy for critical and strategic materials.

It’s also worth noting that Russia also does not appear among the top producers when it comes to clean energy metals, despite being one of the world’s leading producers of minerals like copper, iron, and palladium.

Low Regulation in the Clean Metal Supply Chain

While China leads all countries in terms of cobalt processing, the metal itself is primarily extracted in the Democratic Republic of Congo (DRC). Still, Chinese interests own 15 of the 17 industrial cobalt operations in the DRC, according to a data analysis by The New York Times and Benchmark Mineral Intelligence.

Unfortunately, the DRC’s cobalt production has been criticized due to reports of corruption and lack of regulation.

Part of the Congolese cobalt comes from artisanal mines with low regulation. Of the 255,000 Congolese artisanal miners, an estimated 40,000 are children, some as young as six years old.

The Rise of Clean Energy Metals

The necessary shift from fossil fuels to renewable energy opens up interesting questions about how geopolitics, and these supply chains, will be affected.

In the race to secure raw materials needed for the green revolution, new world powers could emerge as demand for clean energy metals grows.

For now, China has the lead.

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