The cost of aluminum as an anode can be as low as US$
1.1/kg as long as the reaction product is recycled. The total
fuel efficiency during the cycle process in an Al/air EVs can
be 15% (present stage) or 20% (projected), comparable to
that of ICEs. The battery energy density is 1300 Wh/kg
(present) or 2000 Wh (projected), far better than other
electrochemical couples shown in Table 1. The cost of
the battery system chosen is US$ 30/kW (present) or US$
29/kW (projected), far less than the present hydrogen fuel
cell stack (US$ 1219/kW).
We have conducted Al/air EVs life-cycle analysis and
compared the results with that of lead/acid and NiMH EVs.
Only the Al/air vehicles can be projected to have a travel
range comparable to ICEs. The purchase price of aluminum/
air EVs would cost 25–30% more than the present ICEs.With
the decrease in cost of the power train, the purchase price will
likely drop farther. The fuel cost of the Al/air EVs at present is
35% higher than that of ICEs. But with improvement in
battery characteristics, the fuel cost would fall to a level
almost equal to that of ICEs. The life-cycle cost of Al/air EVs
is 14% (projected) and 22% (present) higher than that of
ICEs. Only the lead/acid EVs life-cycle cost is comparable to
Al/air EVs life-cycle cost while the NiMH EVs is the highest.
From this analysis Al/air EVs are more promising candidates,
than lead/acid or NiMH, for replacement of ICEs
considering travel range, purchase price, fuel cost, and lifecycle
cost.