Introduction: the electrification imperative and the implications for the development of igafactories
Brands such as Peugeot, Citroën, Fiat and Mercedes are pivoting to the production of electric vehicles. By 2040, 70% of all vehicles sold in Europe are expected to be electric. With the gradual phase-out of the combustion engine, the demand for efficient and cost-effective battery production is higher than ever before and the need for robust battery production capacity is increasing.
"The price of the battery accounts for 40% of the vehicle price. So if Europe misses the boat on battery production, car manufacturers will be in big trouble," explains Sandrine Cheminaud, Market Development Director, Process Industry at Equans.
To secure its position in battery manufacturing in order to maintain its competitiveness in the global automotive market, Europe is planning to build 20 to 30 gigafactories, for which seven EU Member States have already committed €6bn of investment.
What are Battery Gigafactories?
A battery gigafactory is a large-scale industrial facility that produces large quantities of batteries, mainly for electric vehicles and energy storage solutions. These factories are characterised by their colossal production capacities — often measured in gigawatt hours (GWh) per year— and can meet the battery needs of hundreds of thousands to millions of electric vehicles per year. Gigafactories aim to streamline battery production through high-volume manufacturing processes that can significantly reduce costs due to economies of scale and optimised supply chains.
Sustainable Gigafactories: Innovation and Challenges
The development and operation of gigafactories are complicated processes that require a high degree of cleanliness, safety, precision and protection. The production environment must be tightly controlled to avoid contamination and ensure the integrity of the battery components. For example, the handling of electrolytes — a flammable and toxic substance necessary for the battery to function — requires sophisticated techniques to ensure safety and efficiency.
Another major challenge for the battery industry is managing the end-of-life cycle of batteries. The sustainability of the EV revolution depends not only on production capacities, but also on effective recycling systems.
EU Subsidy for the Construction of German Gigafactory
Construction recently began on a new monumental gigafactory, Northvolt Three, in Heide, Northern Germany. This 4.5 bn euro project, which is subsidised with EU funds, will fundamentally change European battery production. Once operational, the plant is expected to produce enough battery cells to supply one million electric vehicles per year with a maximum annual production of 60 GWh. Such initiatives are crucial, not only for strengthening German production, but also for Europe's endeavours to become self-sufficient in battery cell production and reduce its dependence on non-European suppliers.
The Gigafactory will be powered by locally generated wind energy, in line with the EU's overall environmental goals. This approach emphasises the shift towards more sustainable manufacturing practises and reduces the carbon footprint associated with battery production.
How Does This Affect Equans' Order Book?
For Equans, the rise of battery gigafactories represents a significant business opportunity, particularly in the areas of construction, energy solutions and digital technologies. Equans, which has positioned itself as a leader in the integration and provision of energy and digital solutions for industry, stands to benefit significantly from such large-scale projects.
Equans has already been awarded contracts for the construction and commissioning of several battery gigafactories across the United States and Europe, including Sweden and France, whose Hauts-de-France region is already being dubbed the "Battery Valley."
The company's involvement typically ranges from design and construction work to the advanced installation and maintenance of energy systems, which are crucial for the large-scale and energy-intensive operation of gigafactories. In line with its strategic objectives, Equans is committed to ensuring that its facilities not only meet their production targets, but also lead the way in energy efficiency and sustainability.
- This includes innovative solutions such as geothermal energy storage systems that harness the earth’s stable underground temperatures for efficient heating and cooling in gigafactories. Such systems are essential to maintain the precise environmental conditions required for battery production while significantly reducing energy costs.
- In addition to geothermal power, Equans’ Solar Energy and Storage solutions enable gigafactories to harness solar power, store it efficiently and reduce dependence on non-renewable energy sources. This integration not only supports continuous production cycles, but is also in line with global sustainability goals and reduces the carbon footprint of these industrial giants.
EU financial support and regulatory backing for such projects strengthens Equans' ability to engage in these high-value projects, which will bolster the company's order book and future revenue streams. These developments are timely given the global trend towards electrification and renewable energy sources and will allow Equans to capitalise on new market trends and government incentives.
Equans: A Key Player in Building Sustainable Gigafactories
Equans has carved out a reputation as an expert and agile partner in the construction of gigafactories, bringing its seasoned high-tech expertise to an industry that is still maturing, starting with its involvement in 2018 in the first European gigafactory projects in Sweden.
As gigafactories are complex and require state-of-the-art technologies, Equans’ ability to integrate various technical requirements — from cleanroom standards to chemical handling — is crucial.
The company's approach is characterised by its agility and ability to innovate — qualities that are essential in an industry where rapid adaptation to new technologies and processes is critical. Equans offers comprehensive solutions ranging from planning to maintenance of battery factories. The company leverages its decades of experience in managing complex environments and implementing low-carbon technologies to optimise energy consumption in production processes. The company’s turnkey projects ensure control over every aspect of the factory facility, integrating advanced technologies and ensuring that projects meet the highest international standards for energy efficiency and technological sophistication.
Integrating 4.0 Technology and Sustainable Manufacturing Practices
Equans' commitment to the integration of Industry 4.0 technologies ensures that its gigafactories are at the forefront of digital and physical production capabilities, focusing on critical areas such as advanced process environment equipment, clean room and dry room management and maintenance. The company’s holistic approach includes working with partners in industries such as microelectronics and aerospace, as well as handling volatile electrolytes necessary for battery production, which is critical given the reactivity of the compound with air.
Equans is a pioneer in setting up recycling facilities that can handle the complexity of battery materials, including the recovery of NMP (N-methyl-2-pyrrolidone). This initiative is critical to the future viability of electric car batteries, as efficient recovery and recycling is essential to sustainably closing the production loop.
With these initiatives, Equans is setting an industry benchmark for integrated energy solutions that are both innovative and sustainable, emphasising its role as a pioneer in the global transition to electrification and renewable energy.
Sustainable Gigafactories: The Cornerstone of an Electrified Future
The development of sustainable gigafactories in Europe is a crucial step in achieving the continent's ambitious targets for electric vehicle production. Companies like Equans are leading the charge, driving innovation that takes account of rapid market changes and technological advances. By spearheading large-scale battery production and innovative recycling capabilities, Equans is ensuring that Europe not only moves towards a green automotive future, but also strengthens its position in the global economic landscape and ensures the long-term success of its automotive industry in the age of electrification.
