Unlocking electric vehicles

By  Rebecca Willetts 13 September 2024 8 min read

Our research forecasts that by 2050, a remarkable 97 percent of light passenger vehicles on Australian roads will be electric. In fact, several manufacturers have already announced plans to cease production of combustion engines beyond 2040.

We have consistently been at the forefront of this electrification revolution. We pioneered Australia's first hybrid-electric vehicle in 2000 and developed the battery management system for the nation's first battery gigafactory.

Our deep technical expertise in battery technology and energy systems uniquely positions us to address your questions about the world of EVs. To help shed light on this transformative technology, we spoke to Principal Battery Researcher Dr Adam Best and Kate Cavanagh, our Transport Electrification Team Leader for our Energy Systems Research Program

What is an EV?

Essentially, any vehicle that runs off electrons is an EV, Adam says. This includes:

• Battery electric vehicles (BEVs), which run solely off electricity stored in a battery, range from 16kWh to more than 100kWh.
• Plug-in hybrid electric vehicles (PHEVs), which combine a battery with a combustion engine, are mostly between 7 and 20kWh.
• Hybrid electric vehicles (HEVs) combine combustion engines with a smaller battery than a PHEV. However, they can’t be plugged in to charge. Instead, the battery is charged when the car brakes or slows down, and also by the combustion engine. Their battery size is approximately 0.5 - 2kWh.
• Fuel cell electric vehicles (FCEVs) generate electrons from a reaction between hydrogen and oxygen that generates electricity to either charge a battery or drive a motor.

Comparing battery chemistries

How do EV batteries work?

Just like a phone battery, but bigger!

"EV batteries store electrical energy as chemical energy and convert it back to electrical energy when needed to power the motor," Adam says.

Do you need to install a special charger?

"No. All electric vehicles come with a basic charging cable that you can plug into a standard household power outlet," Kate says.

This method – often called Level 1 charging – might work best for you. However, it is the slowest way to charge your EV.

"For faster and more convenient charging at home, you can install a dedicated EV charger, also known as a Level 2 charger. Public fast chargers are also becoming more widely available as the national rollout of infrastructure accelerates," she says.

How long does it take to charge an EV?

"Charging time depends on the battery size and the charger used. A 70-kWh battery using a Level 2 charger (7.7 kW) would take roughly nine hours to fully charge," Adam says.

"Fast and ultra-fast chargers, or DC chargers, which currently range from 50 kW to 350kW in Australia can drastically reduce this time. Some vehicles can be fully charged in 10 to 15 minutes using one of these fast chargers.

"However, unless you're on a journey that's longer than your vehicle's range, you're less like to be filling up your car all in one go. Our research found that with general daily driving EV drivers only charge their cars to full about once a week.

"While it's a change of mindset to go from a petrol car to an electric vehicle, many people appreciate the convenience of being able to charge their car wherever a standard power outlet is available, rather than needing to go somewhere to fill up," Adam says.

How much does it cost to charge an EV?

The cost to charge an EV can vary significantly depending on how you do it.

"The cheapest option will likely be charging at home during off-peak hours with a time-of-use electricity tariff – or even better, using excess solar power from your rooftop panels, potentially bringing the cost down to near zero. On the other hand, using public fast-charging stations can be the most expensive, with a full charge costing upwards of $30 or more for a 60-kWh battery," Kate says.

"However, with some innovative wholesale electricity providers, you might even get paid to charge your car during specific periods when there's an oversupply of renewable energy in the grid. The actual cost will vary based on your electricity plan and specific circumstances."

How can you maximise your vehicle's range on a single charge?

Adam encourages you to think of your EV battery like your phone's.

"Just as you take steps to conserve your phone's battery life, you can use similar strategies to maximise your EV's range," he says.

• Minimise power-hungry features: Just as running lots of apps drains your phone battery faster, using features like air conditioning, heating, and heated seats will reduce your range.
• Drive smoothly: Hard acceleration and braking are like playing a graphics-intensive game on your phone – they drain the battery quickly. Practice smooth acceleration and coasting to conserve energy.
• 'Eco mode' or similar driving modes: Many EVs offer an 'Eco mode' or similar setting that optimises the vehicle's performance for maximum efficiency, similar to how 'Low power mode' helps extend your phone's battery life.

"In cold weather, you can also keep your vehicle plugged in and use the ‘Departure feature’ offered by some manufacturers," Adam says.

This can ensure that your battery (and cabin!) is warm and toasty while giving you the best range.

What is the lifespan of an EV battery?

While there is some variance, most manufacturers offer warranties between 100,000 and 160,000 kilometres for their EV batteries. Despite this, there have been many anecdotal reports of older EVs with more than a million kilometres on the clock that are still going strong.

"This is supported by research conducted by Jeff Dahn and his team in 2019. With careful design and under optimal conditions, lithium-ion batteries have the potential to power an electric vehicle for more than 1 million miles (1.6 million kilometres)," Adam says.

"They topped this in a 2022 paper outlining the potential for a single battery to last an impressive 4 million miles!"

How can I extend the life of my battery?

Frequent fast charging can accelerate battery degradation. Most car companies recommend relying primarily on slower AC charging at home or work with charger speeds up to 7kW.

"Keeping the charge level between 20 per cent and 80 per cent can also help to extend the life of your EV so you can drive a classic in the years ahead!" Adam says.

What are the typical ownership costs compared to a fossil fuel car?

"EVs have lower fuel and maintenance costs. Electricity is significantly cheaper than petrol. EVs also require less servicing, with no need for oil changes or other traditional maintenance. However, tyre wear can be higher due to the heavier weight of EVs and higher torque on the wheels," Kate says.

What about the driving experience?

Kate adds that EVs are known for smooth, quiet acceleration and responsiveness. Some models offer high-performance capabilities, while others prioritise efficiency and comfort.

Is there a greater risk of fires with EV batteries?

The risk of fire is greater with petrol or diesel cars than with EVs. Adam cautions that while EV battery fires do occur, they are very rare.

What exciting innovations are on the horizon?

"Solid-state batteries are a promising development, offering the potential for higher energy density, faster charging, and improved safety," Adam says.

However, they are still 5-10 years away from mass adoption.

Will we really be able to power our houses from our cars in the future?

"Yes, powering your house from your car in the future is not only possible but increasingly likely," Kate says.

The technology behind this, known as vehicle-to-grid (V2G) or vehicle-to-home (V2H), is already in development and even being implemented in some places. V2H essentially turns your EV into a mobile power bank for your home. In fact, an average EV battery holds enough energy to power a typical Australian household for a few days. While this is promising, there are still some hurdles to overcome, before it is widespread. These include ensuring vehicle and charger compatibility, as well as establishing clear regulatory frameworks to support this technology.

Are there any environmental concerns with EVs?

Though EV manufacturing and battery production impacts the environmental, studies show they have a much lower lifetime carbon footprint than combustion engine cars, particularly when charged with renewable energy. To make it even ‘greener’, research into sustainable mining and battery recycling is ongoing.

What happens at the end of an EV battery’s life?

Australia has yet to see a substantial second-hand electric car market, so the full life cycle of these vehicles is still unfolding. Even when a battery can no longer power a vehicle, it still has the potential for a ‘second life’.

"We are actively researching how these batteries can be repurposed for stationary energy storage applications," Kate says.

Eventually, when a battery reaches the true end of its life, it can be recycled to recover valuable metals like lithium, cobalt and nickel, which can be repurposed for new batteries.

"While this is a complex process, ongoing research is focused on improving recycling processes to ensure that all materials are effectively recovered and reused. Additionally, new battery designs and manufacturing processes are increasingly incorporating end-of-life considerations, paving the way for a more sustainable future."

Do you have any final thoughts?

Kate points out that EVs aren’t just about reducing emissions.

"They offer lower running costs and contribute to a cleaner environment. And they are a lot of fun to drive! With ongoing technological advancements, these benefits will only increase," she says.