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Tesla aims to make breakthrough cell at half the cost, could supply other automakers – Green Car Reports

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Five years ago, Tesla’s collaboration with Panasonic in building its massive Nevada Gigafactory was widely seen as somewhere between an overcommitment and a full-on boondoggle.

The Gigafactory has already proven to be one of the smartest decisions made by Tesla. It assured control over its electric-car battery cell supply, as it ramped up the Model 3 sedan and then Model Y crossover, and helped isolate Tesla from the cell supply issues that have plagued other EV makers.

Tuesday, Tesla announced a new kind of leap ahead. It plans to produce 100 Gigawatt-hours of its new cells by 2022, and 3 Terawatt-hours (3,000 GWh) by 2030—numbers that now put the 35-GWh output of Gigafactory 1 in perspective. Furthermore, supplying other automakers with Tesla cells is a long-term possibility.

As CEO Elon Musk had prefaced on Monday, the company will continue to increase its battery cell purchases from Panasonic, LG, CATL, and possibly other partners supplemental to that ramp-up of Tesla’s own cells—all on the way to what Musk sees as a long-range global target of about 20 million cars per year. 

Tesla Battery Day vertical integration overview

However the new cells—conspicuously absent in physical form as they were at Battery Day—are positioned to be a game-changer. Tesla sums that they could result in a 54% boost to energy density and range, a 56% reduction in cost per kWh at the pack level, and a 69% reduction in overall investment per kWh.

Based on the timing, the gains in energy density, previous hints from Musk, the cells are likely to be installed in the Semi, the Roadster, and possibly the Cybertruck.

Part of the reason Tesla saw the need to go it alone in reconceiving its cells was that even as its products reached greater scale, the battery cost curve was leveling and not improving quickly enough. As Musk and Drew Baglino, senior VP for powertrain and engineering, explained in their Battery Day presentation, it also saw a future in which battery factories, even at 150 GWh each, couldn’t scale up quickly enough to meet anticipated global demand. 

Battery Day. – Current Gigafactory scale not sustainable

Musk called the series of decisions surrounding the new cells as enabling “a new trajectory in the reduction of cell costs,” with differences that the company can start to realize in about 18 months and in fuller effect about three years out. 

One of those decisions involved focusing on a new larger-format cylindrical cell. Tesla considered that as it made cells larger, Supercharging and thermal issues become more challenging. But it found a sweet spot at the 4680-format—or 46 mm wide by 80 mm long, versus 21 mm by 70 mm for the Model 3 and Model Y—with a shingled spiral material and tabless structure permitting a shorter electron path and easier manufacturing. 

Cross-section of future Tesla cell

Tesla says that the 4680 cells offer a better power-to-weight ratio than smaller cells. Each one packs five times the energy and six times the power of Tesla’s smaller cells, with a 16% range boost enabled. Just the form factor itself represents a 14% cost reduction.

Its cell manufacturing to make these uses an adapted form of the straight-from powder dry-coating process pioneered by Maxwell Technologies, a company acquired by Tesla in 2019, although Tesla says that the process has already gone through four iterations since then. 

That process alone allows a reduction in footprint to just one-tenth the manufacturing area for the same energy content, and promises to reduce the energy spent in manufacturing by about the same. 

Tesla also outlined cost reduction and streamlined, vertically integrated processes for obtaining the cathode and anode materials, and noted a simplified pure-silicon anode addition, and a new process through which it hopes to yield refined nickel for the cathode with zero waste water and extract lithium with sodium chloride (table salt).

Future Tesla battery tech will halve costs

In this quest for greater vertical integration, it’s also transitioning to tackle battery recycling in-house, adjacent to the Nevada Gigafactory. 

Adding in the savings from other decisions, Tesla says that it is working toward being able to produce a Terawatt-hour in the space that it took to make a Gigawatt-hour previously, and less space than what Tesla was otherwise currently envisioning for 150 GWh. It would also save 18% in costs per kWh at the pack level.

A so-called pilot facility, capable of producing about 10 GWh of the new cells, is around the corner from Tesla’s Fremont factory, while an actual future plant would make them on the order of 300 GWh. 

Tesla is aiming for high-speed, continuous-motion assembly, and its ownership of Grohmann and Hibar will allow them to internally design and coordinate all the necessary production machines and processes. 

Future Tesla cell will make energy, power gains

Although the Tesla presentation showed whirring cell-making machines and an industrial setting, it didn’t actually show the pilot cell process.

Later in the presentation, Musk confessed why, perhaps: that the process isn’t quite there yet. He described the manufacturing process as “close to working, but not with a high yield.”

Those pressures of scaling up amid the challenges of scaling something completely new haven’t stopped Tesla before. And it didn’t stop Musk from suggesting that Tesla could transition to the role of cell supplier in the future.

“It’s definitely not an intentional effort to keep the cells to ourselves,” he said. “If we can make enough for other companies, we will, we will supply them.”

“Most companies, things slow down,” Musk said. “In this case, they’re going to speed up.”

You can see the full presentation below.

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Telus prioritizing ‘most important customers,’ avoiding ‘unprofitable’ offers: CFO

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Telus Corp. says it is avoiding offering “unprofitable” discounts as fierce competition in the Canadian telecommunications sector shows no sign of slowing down.

The company said Friday it had fewer net new customers during its third quarter compared with the same time last year, as it copes with increasingly “aggressive marketing and promotional pricing” that is prompting more customers to switch providers.

Telus said it added 347,000 net new customers, down around 14.5 per cent compared with last year. The figure includes 130,000 mobile phone subscribers and 34,000 internet customers, down 30,000 and 3,000, respectively, year-over-year.

The company reported its mobile phone churn rate — a metric measuring subscribers who cancelled their services — was 1.09 per cent in the third quarter, up from 1.03 per cent in the third quarter of 2023. That included a postpaid mobile phone churn rate of 0.90 per cent in its latest quarter.

Telus said its focus is on customer retention through its “industry-leading service and network quality, along with successful promotions and bundled offerings.”

“The customers we have are the most important customers we can get,” said chief financial officer Doug French in an interview.

“We’ve, again, just continued to focus on what matters most to our customers, from a product and customer service perspective, while not loading unprofitable customers.”

Meanwhile, Telus reported its net income attributable to common shares more than doubled during its third quarter.

The telecommunications company said it earned $280 million, up 105.9 per cent from the same three-month period in 2023. Earnings per diluted share for the quarter ended Sept. 30 was 19 cents compared with nine cents a year earlier.

It reported adjusted net income was $413 million, up 10.7 per cent year-over-year from $373 million in the same quarter last year. Operating revenue and other income for the quarter was $5.1 billion, up 1.8 per cent from the previous year.

Mobile phone average revenue per user was $58.85 in the third quarter, a decrease of $2.09 or 3.4 per cent from a year ago. Telus said the drop was attributable to customers signing up for base rate plans with lower prices, along with a decline in overage and roaming revenues.

It said customers are increasingly adopting unlimited data and Canada-U.S. plans which provide higher and more stable ARPU on a monthly basis.

“In a tough operating environment and relative to peers, we view Q3 results that were in line to slightly better than forecast as the best of the bunch,” said RBC analyst Drew McReynolds in a note.

Scotiabank analyst Maher Yaghi added that “the telecom industry in Canada remains very challenging for all players, however, Telus has been able to face these pressures” and still deliver growth.

The Big 3 telecom providers — which also include Rogers Communications Inc. and BCE Inc. — have frequently stressed that the market has grown more competitive in recent years, especially after the closing of Quebecor Inc.’s purchase of Freedom Mobile in April 2023.

Hailed as a fourth national carrier, Quebecor has invested in enhancements to Freedom’s network while offering more affordable plans as part of a set of commitments it was mandated by Ottawa to agree to.

The cost of telephone services in September was down eight per cent compared with a year earlier, according to Statistics Canada’s most recent inflation report last month.

“I think competition has been and continues to be, I’d say, quite intense in Canada, and we’ve obviously had to just manage our business the way we see fit,” said French.

Asked how long that environment could last, he said that’s out of Telus’ hands.

“What I can control, though, is how we go to market and how we lead with our products,” he said.

“I think the conditions within the market will have to adjust accordingly over time. We’ve continued to focus on digitization, continued to bring our cost structure down to compete, irrespective of the price and the current market conditions.”

Still, Canada’s telecom regulator continues to warn providers about customers facing more charges on their cellphone and internet bills.

On Tuesday, CRTC vice-president of consumer, analytics and strategy Scott Hutton called on providers to ensure they clearly inform their customers of charges such as early cancellation fees.

That followed statements from the regulator in recent weeks cautioning against rising international roaming fees and “surprise” price increases being found on their bills.

Hutton said the CRTC plans to launch public consultations in the coming weeks that will focus “on ensuring that information is clear and consistent, making it easier to compare offers and switch services or providers.”

“The CRTC is concerned with recent trends, which suggest that Canadians may not be benefiting from the full protections of our codes,” he said.

“We will continue to monitor developments and will take further action if our codes are not being followed.”

French said any initiative to boost transparency is a step in the right direction.

“I can’t say we are perfect across the board, but what I can say is we are absolutely taking it under consideration and trying to be the best at communicating with our customers,” he said.

“I think everyone looking in the mirror would say there’s room for improvement.”

This report by The Canadian Press was first published Nov. 8, 2024.

Companies in this story: (TSX:T)

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TC Energy cuts cost estimate for Southeast Gateway pipeline project in Mexico

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CALGARY – TC Energy Corp. has lowered the estimated cost of its Southeast Gateway pipeline project in Mexico.

It says it now expects the project to cost between US$3.9 billion and US$4.1 billion compared with its original estimate of US$4.5 billion.

The change came as the company reported a third-quarter profit attributable to common shareholders of C$1.46 billion or $1.40 per share compared with a loss of C$197 million or 19 cents per share in the same quarter last year.

Revenue for the quarter ended Sept. 30 totalled C$4.08 billion, up from C$3.94 billion in the third quarter of 2023.

TC Energy says its comparable earnings for its latest quarter amounted to C$1.03 per share compared with C$1.00 per share a year earlier.

The average analyst estimate had been for a profit of 95 cents per share, according to LSEG Data & Analytics.

This report by The Canadian Press was first published Nov. 7, 2024.

Companies in this story: (TSX:TRP)

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BCE reports Q3 loss on asset impairment charge, cuts revenue guidance

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BCE Inc. reported a loss in its latest quarter as it recorded $2.11 billion in asset impairment charges, mainly related to Bell Media’s TV and radio properties.

The company says its net loss attributable to common shareholders amounted to $1.24 billion or $1.36 per share for the quarter ended Sept. 30 compared with a profit of $640 million or 70 cents per share a year earlier.

On an adjusted basis, BCE says it earned 75 cents per share in its latest quarter compared with an adjusted profit of 81 cents per share in the same quarter last year.

“Bell’s results for the third quarter demonstrate that we are disciplined in our pursuit of profitable growth in an intensely competitive environment,” BCE chief executive Mirko Bibic said in a statement.

“Our focus this quarter, and throughout 2024, has been to attract higher-margin subscribers and reduce costs to help offset short-term revenue impacts from sustained competitive pricing pressures, slow economic growth and a media advertising market that is in transition.”

Operating revenue for the quarter totalled $5.97 billion, down from $6.08 billion in its third quarter of 2023.

BCE also said it now expects its revenue for 2024 to fall about 1.5 per cent compared with earlier guidance for an increase of zero to four per cent.

The company says the change comes as it faces lower-than-anticipated wireless product revenue and sustained pressure on wireless prices.

BCE added 33,111 net postpaid mobile phone subscribers, down 76.8 per cent from the same period last year, which was the company’s second-best performance on the metric since 2010.

It says the drop was driven by higher customer churn — a measure of subscribers who cancelled their service — amid greater competitive activity and promotional offer intensity. BCE’s monthly churn rate for the category was 1.28 per cent, up from 1.1 per cent during its previous third quarter.

The company also saw 11.6 per cent fewer gross subscriber activations “due to more targeted promotional offers and mobile device discounting compared to last year.”

Bell’s wireless mobile phone average revenue per user was $58.26, down 3.4 per cent from $60.28 in the third quarter of the prior year.

This report by The Canadian Press was first published Nov. 7, 2024.

Companies in this story: (TSX:BCE)

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