Revolutionary sodium-ion batteries enter mass production: Lithium prices are soaring and this is the cheap, sustainable solution
EVs could become much cheaper thanks, ironically, to the soaring cost of lithium, which is forcing car-makers and battery producers to explore sodium-ion batteries made from abundant materials such as seawater and rock salt.
Supply chain constraints, geopolitical instability and resource volatility linked to lithium production are accelerating efforts to fast-track sodium-ion batteries, which are said to cost around 30 to 40 per cent less to produce.
Leading the race, unsurprisingly, is CATL – the world’s largest automotive battery manufacturer – with its new-generation Naxtra sodium-ion batteries that have already been confirmed for use in passenger vehicles as soon as this year.
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The first vehicle widely tipped to be offered with the new technology is the Changan Oshan 520 sedan (pictured top), which will also feature CATL’s advanced battery-swap capability.
According to CarNewsChina, following successful testing the technology will then be rolled out into undisclosed GAC and JAC models, with a strong possibility that sodium-ion powered vehicles could be available in China before the end of 2026.
Last month CATL also announced plans to mass-produce a new 45kWh sodium-ion battery designed specifically for light trucks and small-to-medium vans.
Rather than focusing purely on cost savings, these new sodium cells are being promoted for their ability to operate at full load in extreme temperatures as low as -30C, conditions in which existing lithium batteries can struggle to perform efficiently.
Commercial vehicles are expected to play a key role in the early rollout of the technology, with sodium-ion batteries also planned for more affordable entry-level EVs as well as stationary energy storage.
Still considered to be at an early stage of development, sodium-ion batteries are known to offer lower energy density per volume compared with lithium technology.
However, their strong cold-weather performance and high levels of safety, including no reported fires during rigorous testing, suggest they have significant long-term potential.
CATL has claimed that within three years it expects sodium-ion energy density to match that of today’s lithium iron phosphate (LFP) cells.
As they stand, sodium-ion batteries are also said to be more robust than current lithium cells, rising by only around 5C in temperature under ultra-fast 5C charging conditions, even without a complex cooling system, potentially allowing car-makers to reduce development costs.
Current sodium-ion energy density ranges from around 100 to 175Wh/kg, while lithium iron phosphate (LFP) batteries typically sit between 180 and 200Wh/kg.
At the top end are ternary lithium-ion cells, used in long-range and higher-performance EVs, which average between 250 and 300Wh/kg.
Next-generation solid-state batteries could significantly exceed this, with projections ranging from 300 to 800Wh/kg.
While sodium-ion cells look promising, demand for lithium is expected to remain strong as battery makers continue to refine ternary lithium chemistries and work towards commercialising solid-state technology.
