A thermodynamic cost floor is the irreducible minimum cost set by the fundamental mass, energy, and material requirements of a chemistry.
The objective reason for believing that sodium is going to make a substantive difference is that the raw materials cost for sodium-based batteries are much lower than they are for lithium-based batteries. And while it’s true that pack cost includes much more than cell cost:
1. Cell costs are still 60 to 70% of pack costs, so cutting cell costs has a big impact on pack costs. It’s not just the cathode costs, many Na chemistries use hard carbon, have no graphite constraints, and there’s no Li plating risks, cutting anode costs.
2. Li pack costs came down substantially as the other systems within them beyond the cell, mainly pack structure, cooling, BMS, and safety, were optimised to suit the particular nature of different Li chemistries over time, and the same process can happen for Na packs.
3. Na chemistries will improve in density, potentially by as much as 40%, whereas LFP has less headroom for improvement, because it’s already doubled through particle morphology control, carbon coating, compaction density improvements, thinner separators, etc.
On top of this, LFP pack manufacturing is highly scaled, optimised for process and yield, integrated along the supply-chain and very capital efficient. By contrast, Na is at an early industrialisation stage, with lower yields, little process-turning, and less equipment optimisation. So there’s plenty of scope for high learning rates and thus large and fast cost reductions.
On top of that, Na competition will spur further Li development. There’s still plenty of areas where we can expect to see advances, from dry electrode coating through to standardisation of larger formats.