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Ascend Elements, a prominent EV battery materials manufacturer, in collaboration with Ernst & Young LLP (EY US), has announced the development of a sophisticated logistics simulation model. This model is designed to streamline operations ahead of the 2025 launch of the Apex 1 manufacturing campus in Hopkinsville, Kentucky. The facility, spanning over one million square feet, aims to support the production of sustainable battery materials sufficient for up to 750,000 electric vehicles annually, employing over 400 individuals.
Key Highlights:
- Partnership with EY US: Ascend Elements has engaged EY US to enhance logistical operations using advanced simulation models.
- Apex 1 Facility: Set to start in Q1 2025, this campus will be North America’s first to produce sustainable pCAM, employing advanced recycling technologies.
- Employment and Production: The facility will create over 400 jobs and produce materials for 750,000 EVs each year.
- Environmental Impact: The operations aim to significantly reduce carbon emissions by utilizing recycled materials.
Rodrigo Almeida, Sr. Director of Supply Chain at Ascend Elements, emphasized the importance of logistics in such a large-scale project: “As you can imagine, a project of this size and scope requires a lot of logistics planning. EY US is using its experience and insight to help us anticipate logistical challenges and optimize our operations to achieve world-class efficiency and minimal impact on the community.”
The Apex 1 site will manage significant daily logistics, including the receipt of truckloads of recycled battery feedstock and the shipment of over 450 metric tons of pCAM materials weekly. The EY US model enables various scenario simulations to optimize plant operations and traffic management. “While the plant will bring new truck traffic to the area, we are actually creating a net reduction of carbon emissions by offsetting the need to ship newly mined battery materials from Asia,” added Almeida.
Felipe Smolka, EY Americas Automotive eMobility Leader, highlighted the strategic importance of these simulations: “Knowledge is power, especially for EV battery material manufacturing and recycling. It’s been impactful working with Ascend Elements to predict possible logistical challenges and opportunities, as the transition planning will help inform manufacturing operations. At EY US, we believe the energy transition is a critical aspect of the automotive industry’s future and one that manufacturers must consider.”
Bruno Feitosa, an industrial engineer at Ascend Elements, detailed the logistical insights gained: “We had a lot of questions about traffic flow and timing that the simulation helped us understand. How many trucks can the site accommodate at one time? Will trucks have room to queue up onsite without creating unnecessary traffic on local roads? How long will it take to load and unload each truck? Do we need to take deliveries 24 hours a day, or can we load and unload in the daytime only? Understanding the answers to these questions is essential to plan for optimal efficiency and safety.”
This project not only positions Ascend Elements as a leader in sustainable battery production but also showcases the potential for significant advancements in environmental sustainability within the automotive industry.
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