Comparison of Costs and Greenhouse Gas Emissions of Long-haul Trucks Powered by Batteries and Fuel Cells

Abstract

This thesis compares the costs and greenhouse gas emissions of long haul trucks powered by battery electric and fuel cell electric technology in Sweden. The study conducts a life cycle assessment of both the trucks, focusing on CO2 emissions during production and use phases, and evaluates the total cost of ownership, considering vehicle cost, fuel, maintenance, and resale value. The data inputs are from literature reviews and previous scientific research. The findings in the scenario analysis highlight that while BETs are effective for urban and regional
transport, FCETs are more suitable for long haul routes. While studying LCA of these trucks, the FCET showed higher CO2 emissions during its lifetime. This emphasizes the need for a mixed approach to decarbonization to achieve sustainable long haul transportation in Sweden.

Popular Abstract

As the transport sector explores cleaner energy solutions, this study evaluates and compares the greenhouse gas (GHG) emissions and total cost of ownership of battery electric trucks (BETs) and hydrogen fuel cell electric trucks (FCETs) for long-haul heavy-duty operations. Before purchasing a BET or FCET for long ranges, factors such as battery charging time, hydrogen refuelling, the frequency of stops, driving patterns, driver rest times, and maintenance all play a crucial role.
This study focuses on two particular phases of these trucks’ life cycle analysis: the production and usage phases. The production phase includes emissions (kg CO₂-eq/km) generated from truck components. Mainly the glider, powertrain, battery pack, fuel cell system, and hydrogen tanks that contribute to the overall carbon footprint.
In the usage phase, the scenario becomes even more dynamic. Operational emissions for BETs are largely influenced by the electricity they use. Thanks to Sweden’s low-carbon grid with a carbon intensity of roughly 0.047 kgCO₂-eq/kWh the emissions per kilometer during operation are impressively low. Yet, the challenge isn’t just about emissions; it’s also about how long the truck has to stop for recharging. It isn’t a surprise that charging a BET for long-haul routes might involve multiple stops to ensure the battery doesn’t drop below a critical state of charge. These stops not only add to the energy cost but also extend driver downtime, increasing labor costs.
On the other hand, FCETs offer the advantage of rapid hydrogen refuelling. With a hydrogen fuel consumption rate of about 9.2 kg/100 km, these trucks can cover long distances with fewer stops. For instance, even though an FCET might need to refuel more frequently in theory due to safety buffers, the actual refueling stops are shorter, often just a few minutes compared to the hours needed for a full battery recharge. This rapid refuelling means lower overall operational downtime and, consequently, lower driver wage costs per trip.
It is interesting to note how these two technologies differentiate when looking at the total cost of ownership over a truck’s first three years. Even though BETs generally have a lower upfront cost, public charging fees and extended charging durations can drive up the per-kilometer cost significantly. This shows how sensitive these cost models are to factors like energy prices, charging infrastructure, and even driver wage rates.
For urban and regional transport, BETs might be ideal due to their lower operational emissions and current well-established charging networks. However, for long-haul routes where every minute counts, FCETs offer significant advantages with their quick refuelling capabilities and longer driving ranges. In summary, this study underlines that the journey toward sustainable long haul transport is complex. It involves a balancing act between production emissions, operational capabilities, better infrastructure, and overall costs.

• author: Javare, Samika Sudesh
• supervisor: Öivind Andersson
• organization: Department of Energy Sciences
• course: MVKM05 20241
• year: 2025
• type: H2 - Master's Degree (Two Years)
• subject: Technology and Engineering
• keywords: Life cycle analysis, LCA, transportation, long haul transportation, TCO, hydrogen fuel cell, battery electric
• report number: LUTMDN/TMPH-25/5614-SE
• ISSN: 0282-1990
• language: English
• id: 9187931
• date added to LUP: 2025-05-05 12:19:32
• date last changed: 2025-05-05 12:19:32