Findings suggest Integrals Power’s material could support applications requiring reliable operation in extreme environments, including automotive, maritime, aerospace and defense sectors.
Read More: https://www.newelectronics.co.uk/content/news/integrals-power-s-lmfp-battery-cells-show-strong-durability-in-independent-tests

The Coradia Continental reportedly features a range of 120 km. The batteries are recharged from the overhead line by means of pantographs at the end stations.
Read More: https://rollingstockworld.com/passenger-cars/germany-inaugurates-first-battery-trains-from-alstom/

In an extreme cold environment of -34 C, the lithium battery, without external insulation measures to keep warm, retained more than 85 percent of its effective capacity after standing for over 8 hours.
Read More: https://www.globaltimes.cn/page/202602/1355177.shtml

For countries building domestic EV manufacturing ecosystems, relying entirely on imported refined inputs introduces structural vulnerability. Battery recycling offers a pathway to reduce that exposure.
Read More: https://www.manufacturingtodayindia.com/inside-indias-battery-recycling-push-securing-materials-for-the-next-phase-of-ev-manufacturing

Once commercialized, Samsung SDI projected that lithium-metal batteries could bolster industries that require high energy density, including advanced wearable devices.
Read More: https://www.upi.com/Top_News/World-News/2026/02/23/Sansung-SDI-lithium-metal-columbia/6531771846486/

With better control over structure and performance, these materials could be used in next-generation batteries and other technologies that require both safety and efficiency.
Read More: https://interestingengineering.com/energy/pil-block-copolymer-battery-conductivity

The first step in custom battery pack manufacturing is understanding the application requirements.
Read More: https://techbullion.com/the-complete-process-of-custom-battery-pack-manufacturing/

The post March at LPI: Battery Industry News and Highlights first appeared on Lithium Power, Inc..

Check out news from the battery industry from February 2026. We’ve compiled the biggest stories from February related to lithium ion batteries, battery manufacturing, recycling, safety and more!

“There’s been an increase of fires at recycling centers and trash stations around the country in recent years, because lithium-ion batteries — the rechargeable batteries — are becoming more and more common.”
Read More: https://buckrail.com/garbage-truck-fire-potentially-linked-to-improper-battery-disposal/

Scientists have been investigating Na-ion batteries as an alternative to Li-ion batteries because of their improved stability and low cost, but several bottlenecks and limitations have blocked the technology’s advancement.
Read More: https://www.livescience.com/technology/engineering/days-numbered-for-risky-lithium-ion-batteries-scientists-say-after-fast-charging-breakthrough-in-sodium-ion-alternative

In addition to significant gains in energy and power density safety tests showed that batteries neither caught fire nor exploded when punctured, and the electrolyte rapidly solidified when exposed to air, preventing leakage.
Read More: https://www.chemistryworld.com/news/lithium-free-battery-breaks-voltage-barrier-for-ultra-cheap-energy-storage/4022825.article

Researchers have devised a box-shaped container that creates a “state of suffocation” that can easily and safely extinguish lithium-ion battery fires if they occur.
Read More: https://www.asahi.com/ajw/articles/16243033

Batteries are no longer just a tech issue or an energy issue – they are a national strategic imperative. The B-MSP aims to equip technicians, engineers, and assembly operatives with the skills necessary to meet future demands.
Read More: https://www.manufacturingmanagement.co.uk/content/news/uk-launches-advanced-battery-manufacturing-training-courses

According to Accurec, their recycling process delivers black mass with a purity of 99%, making it suitable for direct reuse in battery production.
Read More: https://recyclinginternational.com/commodities/battery-recycling/german-recycler-powers-ahead-with-patented-lithium-ion-battery-line/63097/

Check out news from the battery industry from January 2026. We’ve compiled the biggest stories from January related to lithium ion batteries, battery manufacturing, recycling, safety and more!
Read More: https://www.lithiumpowerinc.com/2026/02/06/january-at-lpi-battery-industry-news-and-highlights/

The benefits of Tesla’s new production method extend beyond electric vehicles (EVs). The simplified process is also well-suited to Tesla’s fast-growing grid-scale energy storage business, where cost per kilowatt-hour and manufacturing speed are critical.
Read More: https://driveteslacanada.ca/news/elon-musk-says-tesla-has-solved-dry-electrode-battery-manufacturing-at-scale/

Through integration with Clemson’s e-GRID infrastructure, the systems will enable researchers to evaluate the performance, grid interaction, and system-level behavior of advanced energy storage technologies under conditions representative of real-world power networks.
Read More: https://news.clemson.edu/storen-technologies-deploys-flow-batteries-at-clemson-university-for-grid-integrated-energy-storage-validation/

Battery makers view AI-driven robotics as a new growth opportunity as global demand for humanoid, industrial and logistics robots expands.
Read More: https://www.upi.com/Top_News/World-News/2026/02/03/biz-battery-industry-robot-market-ai-physical-era/7101770170081/

Through its partnership with Nanotech Energy, Amprius establishes an American supply chain for its high-performance cells to support key customers, including L3Harris.
Read More: https://www.morningstar.com/news/business-wire/20260203781679/amprius-secures-strategic-us-based-manufacturing-partner-to-scale-domestic-silicon-anode-battery-production

Corvus is betting that purpose-built drones, designed from the start for harsh freezer conditions, can finally make autonomous inventory a practical reality where traditional automation has struggled.
Read More: https://dronedj.com/2026/02/09/cold-chain-warehouse-drone-inventory/

The post February at LPI: Battery Industry News and Highlights first appeared on Lithium Power, Inc..

As the USA’s demand for lithium-ion batteries soars, developing domestic lithium production has become a national security and supply stability concern which makes tapping America’s brine reserves an important effort.
Read More:  https://finance.yahoo.com/news/newgenium-launches-announces-breakthrough-technology-130000373.html?guccounter=2

“This partnership represents a major step forward in supporting the future of electrification”
Read More:  https://www.bestmag.co.uk/maccor-and-webasto-partner-on-battery-testing/

In 2026, U.S. battery supply will outstrip demand, ending dependency on imports.
Read More:  https://www.reuters.com/commentary/breakingviews/us-battery-autonomy-will-upend-ev-hierarchy-2026-01-02/

Most conventional batteries rely on a liquid electrolyte that allows lithium ions to move between electrodes. All-solid-state batteries replace this liquid with a solid electrolyte, which greatly improves safety.
Read More:  https://scitechdaily.com/scientists-found-a-surprisingly-simple-way-to-improve-solid-state-batteries/

Rice University researchers reveal how they developed a new, cleaner, and more efficient electrochemical approach for recovering lithium.
Read More:  https://newatlas.com/energy/battery-charging-lithium-recycling/

Unlike lithium, a somewhat rare element that is currently mined in only a handful of countries, sodium is cheap and found everywhere.
Read More:  https://www.technologyreview.com/2026/01/12/1129991/sodium-ion-batteries-2026-breakthrough-technology/

The Impervio separator acts as a barrier within the cell to protect it from dendrites and, together with the battery management system, detect the start of thermal runaway.
Read More:  https://www.aerospacetestinginternational.com/features/battery-testing-advances-target-lithium-ion-safety-in-aerospace.html

This move accelerates mass adoption, boosts recycling efforts, and strengthens China’s dominance in global EV markets. Ultimately, it could redefine sustainable electric mobility worldwide.
Read More:  https://www.webpronews.com/china-launches-worlds-first-standards-for-solid-state-ev-batteries/

Short-term material cost fluctuations are driving up lithium battery prices which will impact not only the EV industry buy also data center infrastructure which requires large energy storage systems.
Read More:  https://www.whichev.net/2026/01/08/battery-prices-surge-as-global-lithium-costs-increase/

Lumafield researchers CT scanned over a thousand lithium-ion batteries, explore the hidden risks they uncovered in battery manufacturing defects and quality control inconsistencies.
Read More: :https://youtu.be/-Y23nfAOiXQ

Usually, recycling a battery involves melting the materials into a soup through pyrometallurgy. In direct recycling, researchers soak the cathode in a lithium-rich solution like lithium hydroxide and apply heat or pressure.
Read More:  https://www.rdworldonline.com/how-designer-solvents-are-changing-battery-recycling/

Fire risk remains low when people follow basic safety guidelines: use the correct charger, avoid physical damage (drops, punctures), don’t overcharge, and pay attention to warning signs such as swelling, excessive heat, unusual odors, or smoke.
Read More:  https://www.waste360.com/waste-recycling/why-lithium-battery-ion-safety-and-proper-disposal-matter-more-than-ever

The post January at LPI: Battery Industry News and Highlights first appeared on Lithium Power, Inc..

Some plants are pivoting to making batteries for energy storage or for exported EV batteries, but with the expiration of federal tax credits many EV battery projects are stalled.
Read more: https://evxl.co/2025/11/13/america-28-billion-battery-belt-collapses-ev-demand-craters/

Check out news from the battery industry from November 2025. We’ve compiled the biggest stories from November related to lithium ion batteries, battery manufacturing, recycling, safety and more! Read More: https://www.lithiumpowerinc.com/2025/12/03/november-at-lpi-battery-industry-news-and-highlights/

Learn about the differences between Lithium Ion, LiFePO4, and Na-ion batteries in our latest whitepaper written by Lithium Power, Inc.’s Senior VP of Sales & Marketing, Joel Petersen.
Read On: https://www.lithiumpowerinc.com/2025/12/04/which-battery-chemistry-is-best-for-your-next-project/

In contrast to lithium iron phosphate (LFP), Prussian White offers a sodium-based solution that promises localized supply chains and reduced material costs.
Read More:
https://www.batterytechonline.com/lithium-ion-batteries/building-india-s-s

A new SNC battery factory in New Mexico plans to minimize waste by utilizing a water treatment process that repurposes cooling water from a nearby data center.
Read More: https://www.ess-news.com/2025/12/04/sodium-nickel-chloride-battery-manufacturing-facility-roswell-new-mexico-desert-mountain-energy-proposal/

By pairing the refining unit with LibertyStream’s proprietary direct lithium extraction (DLE) system on existing oilfield infrastructure, the company has demonstrated a modular process that can be replicated in high-volume US basins, such as the Permian and the Bakken.
Read More: https://www.evengineeringonline.com/field-production-of-lithium-carbonate-begins-in-texas/

Lithium-sulfur technology offers the potential to double the energy density of conventional lithium-ion cells, enabling lighter and longer-lasting solutions for electric vehicles, drones, wearables and other applications.
Read More: https://www.bestmag.co.uk/funding-boost-lithium-sulfur-battery-scale-up/

With Christmas gifts such as electric scooters, drones, phones and toys soon to be unwrapped, it is of utmost importance end users understand safe handling of lithium batteries.
Read More: https://cornishstuff.com/health/guidance-issued-on-preventing-lithium-ion-battery-fires/

Despite rising metal prices lithium-ion battery pack prices have fallen to a new record low over the past year.
Read More: https://reneweconomy.com.au/lithium-ion-battery-pack-prices-for-the-grid-plunge-by-45-per-cent-in-past-year/amp/

A slump in EV demand and a global expansion of the Energy Storage System (ESS) market lead Korean makers to shift their focus.
Read More: https://koreajoongangdaily.joins.com/news/2025-12-10/business/industry/Major-Korean-battery-makers-shift-focus-to-LFP-production-in-AI-era/2474180

The post December at LPI: Battery Industry News and Highlights first appeared on Lithium Power, Inc..

Prepared for: OEMs, System Designers & Integrators, Procurement Teams, and Anyone interested in Learning about Batteries.

Foreword

Originally, this was a personal effort. I often get asked about these battery chemistries, and more recently, how Na-ion compares to other widely produced chemistries. I realized I could better address these questions in a whitepaper, so I decided to share it with anyone interested. I hope it is useful and helps clarify a complex topic.

Please consider this paper both as an overview and a summary of the 2025 market and technical reports, including industry reports, major manufacturer announcements, trade press, and recycling studies. It is a compilation of my decades of experience, insights, and trusted industry contacts while also drawing from other industry experts. My goal with this paper is to combine this real-world knowledge with reports and data from across the battery industry spectrum. This makes the document unique in its scope and range of information, providing the reader with valuable insights to make informed decisions about the best battery chemistry for their next project, industry watch, or even targeted investments. 

Additionally, for most people, the word “battery” immediately brings to mind EVs. This connection makes sense; however, the battery cells used in modern EVs are physically different and often specially designed for EV applications, making them less suitable for most other uses. Therefore, when we hear about a new factory or breakthrough chemistry, it’s important to understand that it may have little or no relevance to your specific needs outside of the EV world. For example, Toyota’s new factory in North Carolina. While their cells are very exciting for Toyota products and customers, they have little to no impact or value for other companies or applications outside of Toyota.

Scope, Sources & Methodology

Giving credit where it is due. My words are based on the trust I place in others to publish accurate statistics and forecasts, and I have compiled everything for you, the reader. I thoroughly researched and curated the publications and articles through standard searches, using some AI, mainly Grok-AI. Knowing where to look and whom to trust is important, and I made an effort to double-check for accuracy and cite all sources. 

Primary sources cited throughout include www.MarketsandMarkets.com, industry reports on LFP, CATL/Reuters coverage of sodium-ion activity, and recent recycling and critical minerals analyses (IEA, CAS/industry reviews). Key claims that could change quickly are cited inline. Where possible, market price and adoption figures are referenced to authoritative, recent sources (see citations in the document). The goal is to provide the reader with a practical, procurement-oriented comparison rather than a deep electrochemical primer.

Definition and Overview of each battery chemistry:

*See SWOT for more details on each chemistry

Lithium-Ion

Lithium-ion (NMC/NCA/LCO and other high-energy Lithium-based chemistries). Lithium-ion remains the dominant technology in value and installed capacity in 2025, driven by EVs and portable electronics.  This dominance is not expected to change dramatically until at the earliest 2030, as other chemistries or nuances of Lithium-Ion hit critical mass production and adoption. Global Lithium-ion market spectrum — market value projections for 2025 are large (hundreds of billions USD); MarketsandMarkets shows the Lithium-ion battery market projected at roughly ~USD 190–200B in 2025. 

• Favored for applications needing a cross-section of cell-types (cylindrical, prismatic, pouch), maximum energy density, high discharge rate capability, good temperature range, and stability of the supply chain, including cost-effectiveness when managed well.
• Challenges: safety (thermal runaway risk), reliance on critical minerals (nickel, cobalt, Lithium), and cost volatility.
• Applications: Conventional Li-ion (NMC/NCA, high-energy): ESS, a wide variety of medical devices, industrial apparatuses, consumer electronics, e-Mobility, UPSs, Data storage, and Mil/Aero applications. Passenger EVs, aerospace, high-energy portable electronics, and some performance EVs.

LiFePO₄ (LFP)

LiFePO₄ (LFP) has rapidly expanded in EVs and stationary storage, and lead acid replacement because of lower cost, improved safety, and long cycle life, wide temperature range, and ever-improving energy density; its share of new EV battery deployments has grown strongly, especially in China and for lower-cost EV models. (Dataintelo) LiFePO₄ (LFP) — LFP adoption accelerated 2022–2025 in EVs (cost-sensitive models), e-bus/commercial fleets, and stationary storage; multiple reports place the LFP segment as one of the fastest-growing chemistry markets in 2025. (LFP market valuations reported in the low tens of billions USD for 2025). (Dataintelo)

• LFP (LiFePO₄) has become the low-cost, safe workhorse for many EVs (especially in China) and stationary storage; cell prices for LFP have fallen to the low-$60/kWh range in recent years. (Reuters)
• Rapidly expanding in EVs and stationary storage due to lower cost, better safety, and long cycle life.
• Made in all cell types – cylindrical, prismatic, and pouch.
• Especially strong in China and cost-sensitive EV markets.
• Lower energy density than NMC, but well-suited where safety and total ownership costs are most important.
• In many cases, repurposing LFP cells and packs is a better proposition than other chemistries.
• Challenges: while safety risk is much lower, it still can go into thermal runaway in certain situations, depending on the cell type and configuration. Reliance on critical minerals (Lithium) and a very limited supply chain outside of China. Recycling is not as cost-effective as Lithium Ion. 
• Applications: stationary medical devices, e-Mobility, AMR & AGVs, Truck/RV/Marine applications, and a myriad of applications where lead acid is presently deployed. Stationary energy storage systems (residential to grid), e-buses, commercial fleets, lower-cost EVs, where cycle life and safety / TCO matter more than absolute energy density. Also strong in off-grid solar and industrial backup.

Sodium-Ion (Na-ion)

Sodium-ion is an emerging contender in 2025: major manufacturers (e.g., CATL) moved to pilot and early mass production in 2025, targeting lower-cost stationary and some EV niches where energy density tradeoffs are acceptable. Expect accelerated commercialization 2025–2027. (Reuters)Sodium-ion (Na-ion) — still small in absolute market share in 2025 but fast-growing from pilots to early mass lines; some market forecasts estimate a single-digit % of battery market value by the late 2020s, with 2025 revenues concentrated in consumer power banks, niche EV models, large-small format, and stationary systems. CoherentMarketInsights and other specialized consultancies show multi-billion USD markets emerging by the early 2030s. CATL announced industrial-scale plans in 2025. (Coherent Market Insights)

• Emerging competitor in 2025: pilot and early mass production underway (e.g., CATL Naxtra).
• Strengths: abundant materials, strong safety profile, and potential to be cheaper than LFP at scale. *A key feature is the ability to discharge to zero volts without causing significant cycle life degradation. (See in-depth information in Addendum C.) 
• Challenges and limitations: lower energy density, limited recycling infrastructure, and an early stage of commercialization. Limited cell types do not yet allow for a wide range of application adoption. While some supply is outside of NA, such as www.coulombtechnology.com, the vast majority of suppliers remain in China. 
• Applications: low-cost stationary storage, consumer power banks, some urban EV segments, and commercial vehicles where weight/volume are less critical but cost and safety are prioritized; edge cases where cold-weather performance and supply security are valuable. CATL planned Na-ion EV packs in 2025, targeting both EV and ESS niches. 

Key Takeaways for 2025

• Use high-energy Lithium-ion for premium and range-focused applications.
• Use LFP for mainstream EVs, buses, and energy storage systems.
• Monitor sodium-ion for near-future adoption in low-cost EVs and stationary storage, where density is less critical.
• Supply chain diversification and recycling innovation are strategic imperatives across all chemistries.

Side-by-Side Review of the Unique Attributes of Each Chemistry (Grok-AI)

See Addendum B for more information about other important market segments.

More About Safety — Comparison & Contrast

Thermal Stability/Fire Risk

• Li-ion (NMC/NCA/LCO, high-energy) — higher energy density but more flammable electrolyte and thermal runaway risk if damaged, overcharged, or poorly managed. Device Incidents and pack-level thermal runaway remain the principal safety concerns, mitigated by pack design, especially thermal management, cell-to-cell propagation management, robust packaging, and masterful BMS design. 
• LiFePO₄ (LFP) — significantly better, but not zero thermal/chemical stability than NMC/NCA; much lower tendency to thermal runaway and superior tolerance to abuse (overcharge, high temp). This is why LFP is preferred where safety and cycle life matter.
• Sodium-ion — early 2025 reporting (manufacturer claims, pilot data) indicates sodium-ion packs often have lower fire risk and greater intrinsic safety than NMC chemistries; comparable or slightly better than LFP in some formulations, depending on electrolyte and cell design. However, commercial data at a large scale remains limited. (Reuters)

Operational Temperature & Degradation

• LFP and some sodium chemistries show better low-temperature performance for cycle life and safety margins; high-energy NMC/NCA is still sensitive to temperature extremes and requires more thermal management.
• If temperature extremes are part of the challenge of an application, careful cell selection and seeking out cell makers that specialize in addressing temperature extremes are vital to a safe, robust battery pack. 

Conclusion (safety): LFP and Na-ion lead on intrinsic safety; high-energy Lithium-ion trades safety for energy density and must rely more on system controls and pack engineering. *Cost comparison (2025)

Cell/pack Cost Trends:

• Conventional Li-ion (NMC/NCA): pack costs in the low-hundreds USD/kWh range for mainstream EV packs (varying by cell type, scale, and supplier). Continued cost reductions, but constrained by some critical mineral price volatility. (BSLBATT)
• LiFePO₄ (LFP): among the lowest cost per kWh for Lithium chemistries in 2025 due to abundant iron/phosphate feedstocks, simpler cathode manufacturing, and lack of expensive nickel/cobalt. Many OEMs reported TCO advantages for LFP in lower-range EVs and storage. (Dataintelo)
• Sodium-ion: manufacturers and analysts in 2025 projected lower raw-material cost potential than Lithium chemistries (sodium, cheaper anode/cathode precursors). Some quoted future pack-level targets that could undercut LFP with scale (estimates vary widely). Early commercial products were priced competitively in niche markets; mass cost estimates remain forecasted rather than observed at scale. (Bonnen Battery)
• Important caveat: cost numbers vary by geography, cell format, and degree of vertical integration. Public manufacturer roadmaps (e.g., CATL) suggest Na-ion aims to be cost-competitive with or cheaper than LFP at scale. (Reuters)

*See Addendum A – chart for the 2025 visualized cost per kilowatt comparison

Manufacturability & supply chain

Raw Material Availability

• Li-ion (NMC/NCA): relies on Lithium, nickel, cobalt, graphite, and manganese — several of which (nickel, cobalt, and Lithium) are geopolitically concentrated and face near-term supply/demand tension. IEA and industry reports flag critical minerals as an area of concern. (International Energy Agency)
• LFP: uses iron, phosphate, Lithium (but far less nickel/cobalt). Iron and phosphate are abundant and geographically diversified — easing some supply pressure and enabling broader manufacturing. (Dataintelo)
• Sodium-ion: sodium and many precursor materials are abundant and widely available globally — a strategic advantage for diversified supply chains and cost stability. (Reuters)

Manufacturing Readiness

• Li-ion (NMC/NCA): massive, mature global manufacturing base; high automation and decades of process refinement. Bottlenecks are upstream (active materials, precursor refining) rather than cell assembly. (MarketsandMarkets)
• LFP: well-established cell and pack production lines; many gigafactories retooled or expanded for LFP due to demand. Manufacturing scale-up is straightforward where cell formats are compatible. However, cell manufacturing is highly concentrated in China. Some cell manufacturing is coming online in Indonesia, Taiwan, India, Eastern Europe, and the United States, but all will take several years to have an impact on a global scale. (Dataintelo)
• Sodium-ion: production lines require adaptation but are compatible with existing cell manufacturing infrastructure to a degree. 2025 saw the first industrial lines (CATL Naxtra and others) ramping — manufacturability risk is moderate but improving quickly. (Reuters)

Supply-chain Risks

• Lithium and nickel cobalt exposure remains the highest risk for conventional Li-Ions; LFP and Na-ion provide pathways to diversify away from those pinch points. Trade policy, regional concentration (esp. China for cell production and refining), and mining ramp-up times continue to shape near-term availability. (International Energy Agency)

Deeper into Recyclability & Circularity (Repurposing) 

• Lithium-ion (NMC/NCA): mature recycling methods exist (pyrometallurgy, hydrometallurgy); industry and academia (2024–2025) reported improvements in direct recycling and higher recovery rates in lab/pilot settings, but collection rates and industrial adoption are inconsistent (collection <10% in some regions). Economic viability depends on material prices and scale. (Green Li-ion)
• LFP: chemically simpler (no cobalt/nickel) but recovery of Lithium and phosphate at scale is still developing; recycling economics can be more challenging because LFP cathodes hold less high-value metals compared with NMC. Technologies are adapting to recover Lithium and reuse cell components. (Green Li-ion)
• Sodium-ion: less data at scale (early commercialization). In principle, sodium-based materials are abundant and less valuable, which reduces incentive for conventional metal-value recycling—so new business models (reuse, repurposing, design-for-recycling) and processes must be developed to ensure circularity. (IDTechEx)
• Author commentary: The trait that makes LFP and Na-ion so appealing is also what makes them less desirable for recycling.

Bottom line: recycling systems are evolving. High-value metals (Ni, Co) drive recycling economics today; shifting to LFP/Na-ion changes the economics and requires policy and technology adaptation to maintain circular supply.

The top recycling companies in North America are:

• Redwood Materials – www.redwoodmaterials.com 
• Glencore (formerly Li-Cycle) – www.glencore.com 
• American Battery Tech. – www.americanbatterytechnology.com 
• Cirba Solutions (Retriev) – www.cirbasolutions.com 

Circularity / Repurposing 

More R&D is being conducted to explore and consider reusing (repurposing) used batteries. Virtually all recycling companies have repurposing as a profit center within their businesses, but startup companies and others are also coming to the forefront. It is not an easy proposition! Procuring, transporting the used batteries to the recycling site, disassembly, identifying usable cells and components, and then finding new buyers for the materials is difficult, but potentially lucrative. 

• Ascend Elements – www.ascendelements.com 
• RecycLiCo – www.recyclico.com 
• KULR / Cirba – www.kulr.ai 
• Princeton NuEnergy – www.pnecycle.com
• Green Li-ion – www.greenli-ion.com 

Primary applications for repurposed batteries (Green li•ion)

• Stationary Energy Storage Systems: Used to store renewable energy (e.g., solar or wind) for grid support or peak shaving, extending battery life by 5–10 years in low-demand scenarios. 
• Backup Power Systems: Deployed in critical infrastructure like hospitals, data centers, and telecommunications for uninterruptible power supplies during outages. 
• Microgrids: Integrated into off-grid or resilient energy setups, such as solar PV + battery microgrids for remote communities or military bases, as seen in California Energy Commission-funded projects. 
• Renewable Energy Integration: Paired with solar or wind farms to balance intermittent power generation and feed excess energy back to the grid. 

SWOT Analyses

Lithium-ion (high-energy NMC/NCA)

• Strengths: highest energy density; mature manufacturing and supply chains for cells and packs; proven performance in EVs and consumer devices. (MarketsandMarkets)
• Weaknesses: reliance on limited minerals (Ni, Co, Li); higher intrinsic fire risk; cost volatility linked to critical minerals. (International Energy Agency)
• Opportunities: high-performance vehicles, energy-dense applications, and ongoing cost reductions through cell innovation and recycling improvements. (MarketsandMarkets)
• Threats: commodity supply shocks, regulatory and safety pressures, competition from LFP and Na-ion in certain segments.

LiFePO₄ (LFP)

• Strengths: excellent thermal safety, long cycle life, lower-cost inputs (iron/phosphate), strong for ESS and many EV segments. (Dataintelo)
• Weaknesses: lower energy density compared to NMC/NCA (heavier/larger for the same range), recycling economics less influenced by high-value metals. (Green Li-ion)
• Opportunities: continued adoption in EVs (budget/medium segments), grid storage, and markets where safety is critical. (solarctrl.com)
• Threats: potential displacement in high-range EVs and pressure if Na-ion reaches cost parity with similar safety.

Sodium-ion (Na-ion)

• Strengths: abundant raw materials (sodium), potentially the lowest raw-material cost, good intrinsic safety, and emerging manufacturability. (Reuters)
• Weaknesses: lower energy density than NMC (and often LFP), nascent recycling ecosystem, limited commercial track record at scale (2025). (IDTechEx)
• Opportunities: stationary storage, low-cost EV segments, geographic supply diversification for nations lacking Lithium resources. (Reuters)
• Threats: failure to meet promised cost/energy milestones, improvements in incumbent chemistry, and market conservatism slowing adoption.

Strategic Implications for OEMs and System Integrators

1. Segment-fit strategy: Match chemistry to application — choose high-energy Li-Ions where range/weight is key; choose LFP/Na-ion for cost-sensitive or safety-critical systems. (Dataintelo)
2. Supply-chain resilience: Diversify cathode sources and consider long-term contracts for critical precursors; evaluate LFP or Na-ion where regional supply risk for nickel/cobalt/Lithium is unacceptable and requires immediate attention to scale.
3. Design for circularity: Invest in battery collection, design-for-disassembly, and support for direct/hydrometallurgical recycling — economics will shift as chemistries change. (Green Li-ion)
4. Pilot sodium-ion where it fits: Monitor Na-ion commercialization and run pilot programs in non-critical or stationary segments to validate claims before large-scale adoption. 

Risks & Open Questions (to monitor in 2025–2027)

• Will sodium-ion meet cost and energy targets at an industrial scale? (CATL rollout is a key point to watch. As they go, others will follow.)
• Will critical minerals supply/demand dynamics tighten or loosen in the short term (pricing and policy interventions)? International Energy Agency (IEA) and market signals should be monitored.
• Will cell manufacturing of all chemistries spread beyond what China is producing?
  • If so, where?
  • At what speed?
• How quickly will recycling technology and regulations develop to alter the economic calculus for each chemistry?
• For emerging technologies, will the investment community step up their speculation portfolio to quicken the pace in North America and beyond?

Selected References

• MarketsandMarkets — “Lithium-ion Battery Market Size” (2025 market estimates). (MarketsandMarkets)
• Industry/LFP market reports (various 2024–2025 analyses). (Dataintelo)
• CATL / Reuters coverage — CATL launches sodium-ion brand (Naxtra) and mass-production plans (2025). (Reuters)
• SodiumBatteryHub and IDTechEx market commentary on Na-ion commercialization outlooks (2025). (SodiumBatteryHub)
• Recycling & critical minerals analyses — CAS/industry recycling reports and IEA critical minerals outlook (2024–2025). (web.cas.org)

Final Thoughts and Recommendations

• For OEMs: consider adopting a mixed-chemistry strategy when feasible. Conduct thorough research to ensure the chemistry you select is optimal for your application. NMC/NCA, LFP, Na-ion, or potentially other emerging chemistries might be the best option, but maybe not.
• For stationary ESS and integrators: prioritize LFP today for safety and TCO; evaluate Na-ion pilots in cost-sensitive projects where energy density is less critical.
• For policy and recycling stakeholders: accelerate collection infrastructure and invest in direct and hydrometallurgical recycling to reduce reliance on virgin critical minerals.
• Adopt a robust partnership with the best pack assembler for your needs. Just as there are many cell types, chemistries, and unique cell attributes, virtually every pack assembler has a specialty, and one “size” does not fit all when it comes to pack assembler capabilities. 

Addendum A – Cost Comparisons

2025 Battery Cost per kWh Comparison Analysis

Battery costs in 2025 continue to decline due to economies of scale, stabilized raw material prices, and manufacturing advancements, especially in China. Lithium-ion batteries (mainly NMC chemistry) average around $100 per kWh at the cell level, driven by higher nickel and cobalt content but benefiting from mature production. LiFePO4 (LFP) batteries, favored for stationary storage and cost-sensitive EVs, have dropped below $60 per kWh, making them 30-40% cheaper than NMC equivalents based on industry benchmarks. Sodium-ion (Na-ion) batteries, an emerging option using abundant sodium, show promising cost reductions with projections near $50 per kWh. However, real-world deployment remains limited, and claims of sub-$20 per kWh (e.g., from CATL) face scrutiny amid scaling challenges. These figures focus on cell-level costs for fair comparison; pack-level costs add 20-50% more.

The bar chart below visualizes these approximate 2025 cell costs for a direct side-by-side analysis.

Key Price/Cost Related Insights:

• Cost Leadership: LFP remains the leader for volume applications, but Sodium-Ion could challenge this if it hits $40/kWh at scale by late 2025. 
• Trends: Expect a 10-20% price decrease across all technologies by 2026, with Sodium gaining ground in grid storage due to lower material volatility. 
• Caveats: Prices are cell-level estimates from mid-2025 reports; actual prices vary by region, volume, and supply chain. For EVs, NMC possessing higher energy density justifies a premium.

Addendum B – Key Applications & Marketplaces

Much of the data available is driven by the EV marketplace. However, a deep dive into some key market segments is quite revealing for the Lithium battery usage: Source: (Grok-IEA or BloombergNEF)

Medical Devices

Handheld and Industrial Controls

Solar and Off-Grid devices

AMRs and AGVs

Estimated Annual Production of Lithium Battery Cells for AMRs and AGVs

Based on ~140,000 units shipped in 2025, with ~75% adopting Lithium-ion batteries (~105,000 units), and an average of 100 cells per pack:

• Total Cells Produced: ~10.5 million cells annually.
  • Breakdown: ~8 million for AMRs, ~2.5 million for AGVs.
  • Including replacements: Could rise to ~15 million cells (adding ~4.5 million for ~45,000 replacements).

This estimate aligns with the Lithium battery market for AGVs/AMRs, valued at ~USD 800-900 million in 2025 (part of the broader USD 1.57 billion market by 2031, growing at 10-12% CAGR). At an average cell cost of ~USD 5-10 (for industrial-grade LFP prismatic cells), this supports the volume.

Truck and RV Start & Auxiliary (Non-EV)

Data on specific cell production volumes worldwide is limited, as most industry reports categorize Li-ion production into broader groups (for example, EVs account for about 70% of demand). Non-EV truck and RV uses are estimated to make up 1–3% of total Li-ion cell production based on market segmentation. 

Total global Li-ion cell production reached approximately 2,500 GWh in 2023 and is expected to surpass 3,000 GWh in 2025. For the segment in question, annual cell production is conservatively estimated at 10–25 million cells in 2025, based on market sizes and average battery configurations (e.g., 4–8 cells per 12V pack), and adoption rates (5–15% in heavy-duty trucks initially; 20–30% for RV auxiliary systems). 

This equates to approximately 5–15 GWh of capacity, a small part of the roughly 700 GWh used for non-EV automotive applications overall.

Humanoid Robotics (This is interesting)

Estimated Annual Number of Battery Cells

To derive cell counts, we use average pack specifications from leading humanoid models (e.g., Tesla Optimus, Figure 01, Boston Dynamics Atlas). A typical humanoid battery pack is 1.5–2.5 kWh, built from 40–100 cylindrical cells (3.6–4 V nominal per cell, 3–5 Ah capacity). Pouch or prismatic cells (fewer but larger) are alternatives in some designs. (Grok-AI search results)

Addendum C – Discussion of Na-ion and Zero-Volt Discharge Capability

Overall, compared to Li-Ion and LiFePO4 (LFP), a major advantage of Sodium-ion (Na-ion) batteries is their ability to be discharged to 0V with almost no cell damage. With Na-ion, this is considered safe and reversible. This is one of the key practical benefits of Na-ion over lithium-ion and LFP. 

Interestingly, Lithium Titanate Oxide (LTO) is a lithium chemistry that is also safe and can be reversed down to 0V.

Why Na-ion batteries tolerate 0 V well:

1. No copper dissolution
   • Most Na-ion cells use aluminum as the negative current collector, unlike copper in Li-ion cells. Copper dissolves above approximately 0.8–1 V vs. Li/LFP when over-discharged in Li-ion cells, causing irreversible damage. In contrast, aluminum does not dissolve or corrode significantly at low voltages, so even if the cell drops to 0 V, the current collector remains intact.
2. Hard carbon anode behavior
   •  The most common anode in commercial Na-ion cells is hard carbon.
   • Hard carbon can be fully de-sodiated (meaning “fully discharged,” with all sodium ions removed) without causing structural damage, and its potential plateau ends very close to 0 V.
   • For many manufacturers (e.g., HiNa Battery, Farasis, CATL), their datasheets explicitly specify discharge to 0 V or 0.1 V.
3. Cathode stability
   •  Common cathodes, including layered oxides, Prussian blue analogues, and polyanionic compounds, are stable when all sodium ions are fully removed. Prussian blue analogues (PBA), or “Prussian Blue-like,” as CATL refers to them, are especially tolerant and are routinely cycled down to 0 V in commercial products. Natron, now out of business, used PBA.

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QuantumScape has sent out it’s most advanced solid state battery cell samples yet.

Read More: https://www.electrive.com/2025/10/24/quantumscape-delivers-b1-samples-of-its-solid-state-battery-cell/

The International Air Transport Association are making an effort to inform travelers of safe and unsafe practices when travelling with lithium ion batteries, an ever-growing concern.

Read More: https://gulfbusiness.com/powerbank-phones-laptops-iata-rules-you-must-know/

When introduced into an old, tired battery, lithium rich salts show promise for renewing the ability of lithium battery cells to accept and deliver charge again!

Read More: https://www.earth.com/news/new-lithium-tech-helps-battery-charge-over-12000-times-without-losing-power/

Chinese companies are world leaders in battery technology and new export restrictions coming into play leave companies that rely on Chinese tech hustling to get the materials they need out of the country ASAP.

Read More: https://www.reuters.com/world/china/reliance-races-get-battery-gear-orders-out-china-ahead-export-curbs-sources-say-2025-10-24/

Test data shows Sakuu dry-process cathode performance at the forefront of commercially available lithium-ion batteries.

Read More: https://www.voxelmatters.com/sakuu-proves-commercial-viability-of-3d-printed-battery-electrodes/

China produces more than three-quarters of all lithium-ion batteries worldwide and is home to six out of the 10 largest battery makers on the planet.

Read More:https://www.bbc.com/future/article/20251110-how-china-won-the-worlds-battery-race

With a dip in EV demand sodium-ion battery suppliers are converting production lines to supply ESS units.

Read More: https://pulse.mk.co.kr/news/english/11460063

Sodium-ion batteries support faster charging and discharging, operate across a wide temperature range, and take advantage of locally available raw materials in Europe.

Read More: https://www.ess-news.com/2025/11/06/spanish-startup-bihar-batteries-to-commercialize-its-sodium-ion-batteries-in-2026/

In an effort to secure essential supply chains and reinforce U.S. Energy independence Clarios is prioritizing battery recycling and critical mineral processing at its South Carolina facility.
Read More: https://www.berkshireeagle.com/online_features/press_releases/clarios-accelerates-plans-to-build-significant-new-u-s-battery-recycling-and-critical-mineral-processing/article_e795cb47-c707-535a-9f67-9e432a480ba6.html

The post November at LPI: Battery Industry News and Highlights first appeared on Lithium Power, Inc..

A new factory in Moses Lake, WA will produce silicon-dominant anodes which can increase lithium-ion battery density by up to 20%.

Read More: https://www.webpronews.com/sila-opens-moses-lake-factory-for-20-boost-in-ev-battery-density/

With their Optimized Lithium & Graphite Recovery (OLiC) process Cylib is able to recover over 90% of critical materials from spent batteries. A massive new facility in Europe will utilize this technology to help Europe in it’s pursuit of raw materials independence.

Read More: https://www.startbase.com/news/cylib-erhaelt-261-millionen-euro-eu-foerderung-fuer-batterie-recyclinganlage/

At a rate nearly 3x the industry standard, Ateios Systems and Kodak’s electrode coating system could allow for up to 96% reduction in energy consumption, elimination of PFAS-based chemicals from the process, and recycle-ready electrodes.

Read More: https://batteryindustry.net/ateios-systems-and-kodak-redefine-battery-manufacturing-with-high-speed-solvent-free-electrode-production/

Solid-state lithium-ion batteries promise improved safety, energy density and service life and every step forward is important. A new polymer drastically reduces the unstable interface commonly understood as a central problem of solid-state batteries.

Read More:https://www.electrive.com/2025/10/08/new-polymer-to-improve-solid-state-batteries/

Lithium battery manufacturing and recycling is one of the nation’s most critical and fast-growing technology sectors. Funded by National Science Foundation’s ExLENT a team of MIT and Clemson personnel are working to develop a strong workforce pipeline for the industry.

Read More: https://batteriesnews.com/clemson-university-mit-and-industry-join-to-build-battery-workforce/

While typically safe, lithium-ion batteries used in the electronics we use daily can pose a fire hazard and the National Fire Protection Association wants users to understand how to handle, use, and properly recycle these products.

Read More: https://www.gmtoday.com/the_freeman/news/battery-recycling-safety-tips/article_52bfdd8f-2ad7-5b03-8fc8-8dd5658a03cc.html

Shmuel De-Leon, CEO of De-Leon Energy, discusses solid state batteries and the importance of US support for battery development.

Read More: https://www.autonews.com/podcasts/shift/an-shift-podcast-shmuel-de-leon-solid-state-ev-batteries-1012/

By removing the need for a dedicated anode structure, Panasonic can pack more capacity into a battery without increasing it’s size.

Read More: https://www.electronicdesign.com/markets/automotive/article/55320979/electronic-design-panasonic-aims-for-anode-free-ev-battery-by-2027

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Connect with Lithium Power, Inc. at The Battery Show 2025! We will be at Booth #6622 ready to discuss our latest lithium ion battery technologies driving efficiency, sustainability, and performance in multiple markets.

Post’s Link:https://www.lithiumpowerinc.com/2025/07/23/the-battery-show-2025-lithium-ion-batteries/

Lithium battery recycling is essential for long-term sustainability in the energy sector as it reduces environmental impact as well as secures access to a valuable resource.

Post’s Link:https://www.innovationnewsnetwork.com/new-research-uncovers-the-environmental-benefits-of-lithium-battery-recycling/60800/

Explore the exciting future of battery technology as 3 experts in their fields discuss the why, what and how of battery innovation beyond lithium ion.

Post’s Link:https://www.azom.com/article.aspx?ArticleID=24429

Take a look at the process Botree Recycling, a Chinese start-up, uses to extract lithium, nickel, and cobalt from dismantled lithium-ion batteries to bolster the supply of these important minerals.

Post’s Link:https://www.weforum.org/videos/chinese-start-up-recycles-lithium/

LG Energy Solution emphasizes the growing importance of local production and supply chains as it becomes the first company to begin mass production of ESS battery cells in the US.

Post’s Link:https://www.koreaherald.com/article/10565271

A new membrane helps to power the next-generation “flow battery” which could allow for far more cost-effective solar energy storage batteries when compared to lithium.

Post’s Link:https://scitechdaily.com/inexpensive-new-liquid-battery-could-replace-10000-lithium-systems/

Lithium Power, Inc. is excited to announce our participation in The Battery Show 2025, the premier event for everything related to batteries: future technologies, breakthroughs, manufacturing, supply chain, and logistics. 

Post’s Link:https://www.lithiumpowerinc.com/2025/07/23/the-battery-show-2025-lithium-ion-batteries/

When batteries are no longer useful for vehicles they may still have value for other uses, this company aims to save valuable resources by repairing and remanufacturing cells for new long-term use applications.

Post’s Link:https://www.electrive.com/2025/09/03/fraunhofer-pilot-plant-carefully-dismantles-batteries-down-to-the-cell-level/

With an average volumetric energy density of ~919Wh/L and fast charging rates reaching 100% charge in 39.5 minutes, the Enovix AI-1 smartphone battery represents a significant advancement specifically targeted at smartphones.

Post’s Link:https://www.manilatimes.net/2025/08/27/tmt-newswire/globenewswire/independent-testing-confirms-enovix-ai-1-battery-as-industrys-highest-energy-density-smartphone-battery/2174573

Instead of focusing on metal recovery in recycling, this newly developed method opts to electrochemically convert lithium manganese oxide into manganese ions for use in zinc-manganese redox flow batteries.

Post’s Link:https://tech.yahoo.com/science/articles/scientists-astonishing-breakthrough-using-old-200000350.html

The post September at LPI: Battery Industry News and Highlights first appeared on Lithium Power, Inc..

One key aspect of supply chain resilience for lithium battery raw materials is recycling. An industry-academia consortium in the UK hopes to advance zero-emission automotive manufacturing while securing better onshore supply of critical battery materials.

Read More: https://www.machinery-market.co.uk/news/40330/Consortium-to-accelerate-lithium-ion-battery-recycling

Stop by our booth at The Battery Show 2025 to learn all about how Lithium Power, Inc.’s LiCore80 Battery Management System (BMS) delivers superior value and an unmatched feature set.

Read More: https://www.lithiumpowerinc.com/2025/07/23/the-battery-show-2025-lithium-ion-batteries/

Durability and safety are key to lithium-metal battery adoption in everything from vehicles to energy storage infrastructure, South Korean researchers are employing a dry transfer technique for anode coating to enhance safety and reliability.

Read More: https://i-hls.com/archives/130382

Extended Producer Responsibility (ERP) regulations hold battery producers accountable for the entire lifecycle of their products, but it takes responsibility from all stakeholders, from producers, to users, to regulatory bodies a holistic end-of-life battery management system will be essential to a sustainable future.

Read More: https://africa.com/the-importance-of-a-robust-end-of-life-battery-management-system-in-south-africa/

Discover our latest lithium-ion battery technologies at booth #6622, October 6-9. Our solutions are designed to drive efficiency, sustainability, and performance in material handling systems, medical, industrial, ESS/Solar, LEV, E-Mobility, and beyond, offering unmatched reliability, safety, and cost-effectiveness. 

Read More: https://www.lithiumpowerinc.com/2025/07/23/the-battery-show-2025-lithium-ion-batteries/

With growing interest in alternatives to traditional wet-coating processes, LiCAP will begin supplying samples manufactured with their proprietary “Activated Dry Electrode” process for lithium-ion, solid-state, and sodium-ion battery electrodes.

Read More: https://www.electrive.com/2025/08/05/licap-launches-300-mwh-dry-electrode-line-in-california/

ProLogium believes they’ve revealed another “Holy Grail” for its battery platform which utilizes a combination of non-combustible materials and active thermal risk control to bring new levels of safety to solid-state lithium batteries.

Read More: https://www.globenewswire.com/news-release/2025/08/07/3129380/0/en/ProLogium-Debunks-the-Solid-State-Battery-Safety-Myth-with-Breakthrough-Dual-Protection.html

Can Artificial Intelligence prevent thermal runaway? SGS and Chongqing Energy College aims to improve fire safety using the world’s first AI-powered, fully automated thermal runaway testing system.

Read More: https://news.europawire.eu/sgs-and-chongqing-energy-college-unveil-advanced-ai-based-automated-thermal-runaway-testing-system-for-battery-energy-storage-safety/eu-press-release/2025/08/08/14/50/18/160421/

Volexion’s first graphene-coated cathode active materials (CAM) have shipped. Harnessing the power of graphene promises to allow longer lasting, faster charging, and higher density lithium ion batteries.

Read More: https://www.reuters.com/press-releases/graphene-battery-era-volexion-delivers-coated-cathode-materials-2025-08-06/

High recyclability, 25 year lifespan, and increased safety are just some of the potential benefits of Vanadium Flow Batteries for scalable energy storage.

Read More: https://www.batterytechonline.com/stationary-batteries/vanadium-flow-batteries-are-gaining-traction-vanitec-ceo-explains-why

A first of its kind Battery Manufacturing Skills Pathway in the UK aims to address the critical battery manufacturing skills gap to enable the region to reach its Net Zero ambitions.

Read More: https://www.themanufacturer.com/articles/atlas-copco-and-university-college-birmingham-partner-to-address-uk-battery-manufacturing-skills-gap/

“Many consumers believe that products on the market have been reviewed for safety by regulatory agencies. But the truth is that fewer than 1% of products on the market overseen by the Consumer Product Safety Commission (CPSC) must comply with a mandatory safety standard.”

Read More: https://www.batterytechonline.com/testing-safety/battery-infernos-why-99-of-products-lack-mandatory-safety-testing

The post August at LPI: Battery Industry News and Highlights first appeared on Lithium Power, Inc..

While giants like CATL, BYD, and Panasonic have the resources for massive R&D investments and manufacturing scale, there’s tremendous innovation happening at smaller companies that can move more quickly and take bigger risks on breakthrough technologies.
These ten startup companies are focused on solving specific technical challenges that the large manufacturers might see as too risky or niche.

Read More: https://www.batterytechonline.com/market-analysis/10-energetic-battery-startups-worth-watching-in-2025

Is the UK the next hotspot for Battery Tech? What do you think?
Focusing on sophisticated battery tech like solid-state, lithum-sulfur, and sodium ion systems, a multi-year investment in sustainable battery technologies aims to position the UK as a global leader in the clean energy game.

Read More: https://technologymagazine.com/articles/uk-unveils-us-621m-battery-innovation-drive

Vast amounts of data, inconsistent reporting, and a lack of standardized performance metrics slows lithium-metal battery innovation, that’s why University of Surrey scientists hope to develop an AI-driven public database to serve as a crucial resource for researchers.

Read More: https://www.azom.com/news.aspx?newsID=64704

Future tasks will ask a lot more of humanoid robots than we do now and issues with performance, weight, and capacity are big issues that many researchers are working to solve.
Read More: https://english.news.cn/20250630/587a51d51e82417dbf9673db4bf0e03f/c.html

Due to policy uncertainties, stock prices have been in limbo, but there is some expectation that the secondary battery sector has bottomed out.

Read More: https://www.businesskorea.co.kr/news/articleView.html?idxno=246179#google_vignette

Big strides are being made by China’s lithium battery industry as they have developed full-process coverage for mass commercial production of solid-state batteries.

Read More: https://global.chinadaily.com.cn/a/202507/04/WS68673cb8a31000e9a573a257.html

Panasonic leads the way! DeSoto, KS, is now the focus of cylindrical EV battery cell technology made in America. “As the largest economic development project in Kansas state history, the factory is expected to create up to 4,000 direct jobs and approximately 8,000 jobs in total, including those in supplier and related industries.”

Read More: https://www.automotivedive.com/news/panasonic-energy-opens-kansas-ev-battery-plant/753146/

Connect with Lithium Power, Inc. at The Battery Show 2025! We will be at Booth #6622 ready to discuss our latest lithium ion battery technologies driving efficiency, sustainability, and performance in multiple markets.

Read More: https://www.lithiumpowerinc.com/2025/07/23/the-battery-show-2025-lithium-ion-batteries/

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