Electricity and Control December 2024

ENERGY MANAGEMENT + THE INDUSTRIAL ENVIRONMENT

Building sustainable battery gigafactories Peter Hodgkinson, Director for Strategic Growth and Major Projects: Property & Buildings, WSP in Africa Battery gigafactories have a critical role to play as more countries and industries embark on meeting net zero targets and transitioning to renewable energy sources. Access to more efficient, scalable, and environmentally sustainable battery manufacturing capabilities can assist stakeholders to achieve these objectives faster. T hree core markets are driving the growth of battery manufacturing – battery energy storage solutions (BESS); electric vehicles (EVs), and consumer elec tronics (rechargeable appliances).

Peter Hodgkinson, WSP in Africa.

Battery manufacturing boom Currently, there are reportedly 369 gigafactories [1] in the pipeline around the world, to be completed by 2030. Not too long ago this number was 115. According to statista.com, the global demand for batter ies is expected to increase [2] from 185 GWh in 2020 to over 2 000 GWh in 2030. Furthermore, the value of the lithium-ion battery market worldwide is projected to top $193 billion by 2028 [3] reflecting a 23.3% compound annual growth rate from 2021. This has proven to be the catalyst for the con struction of sustainable and efficient battery gigafactories. Research by EVMarketsReports.com [4] , shows invest ments in battery gigafactories reached $131 billion in 2022, a 24% increase over the previous year. These were led by China – showing a 65% year-on-year increase – and North America with its manufacturing capacity expanded by 49% in 2022. Modifying existing facilities From new builds to refurbishing and converting previously used manufacturing facilities or expanding existing tradi tional battery manufacturing facilities to gigafactories, se curing these investments requires a holistic approach that encompasses construction, optimisation, power supply, site selection, feedstock sourcing, sales strategy, regulato ry compliance and a sustainability lens. Existing facilities can be retrofitted to transform them into battery gigafactories by adopting an integrated approach that looks to reuse as much of the existing buildings, servic es and equipment at the facility as possible, even though there may be limitations. However, the plants are technical ly complex, requiring deep knowledge in the new genera tion of gigafactories, as well as specialist expertise in clean and dry room design and implementation. Minimising risk Managing the risks in retrofitting facilities to become battery gigafactories requires thorough studies. These may include geotechnical and environmental assessments, evaluating flood risks, considering climate change, and checking for

Battery energy storage for renewable energy plants is one of the core markets driving growth in battery manufacturing. ground contamination. Identifying materials such as asbes tos and conducting concrete integrity testing are critical to gauge the effects of age and chemicals. A documentation search should include existing draw ings, reverse engineering, and reviewing maintenance re cords by consulting with on-site personnel and third-party vendors. Ensuring safety not only in the structural and civ il aspects of the construction but also in mechanical and electrical services, is essential. Building Information Mod elling (BIM) enhances upfront planning and coordination in modelling the space, which is key to reducing risks and ensuring an efficient project timeline. Improving energy efficiency How to improve the energy efficiency of an existing fac tory is a fundamental question. This is where developing sustainable battery gigafactories requires a combination of international experience and local insights. Working with the permitting and local authorities on es tablishing site boundaries and zoning rights and maintain ing compliance with national and local regulations is also required. So too is an understanding of the environmental conditions of where the existing facility is situated. Factors such as the humidity, the climate, the potential impact of climate change, need to be considered. Decision makers should be aware that the building typically accounts for less than one third of construction CAPEX, and services and utilities constitute most of the

DECEMBER 2024 Electricity + Control

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