Future Projections of Lifecycle Cost and Greenhouse Gas Emissions of Light-Duty Vehicles
Abstract
1. Introduction
2. Computations in CarGHG
2.1. Overview
2.2. Model Inputs
2.2.1. Scenario Parameters
2.2.2. Other Inputs and Parameters
- Set of vehicle models to be analyzed/compared, including Powertrain type and nominal all-electric range (AER) for plug-in vehicles, i.e., BEV, PHEV or PFCEV.
- Complete FASTSim model (separate file for each vehicle): among the information included is (depending on powertrain type) sizing (in kW) of the engine, motor or fuel cell, as well as the type of fuel used in the engine (Gasoline, Diesel or Natural Gas), sizing (in kWh) and power capacity (in kW) of the traction battery, total mass of the vehicle and mass of the vehicle excluding the traction battery.
- Designation (for each vehicle in the set) of whether the vehicle model is “virtual” or approximately based on some real model with available market data:
- ▪
- If the vehicle model is not designated as virtual, the average purchase price from market data (or any other means of estimation) is required as an input;
- ▪
- If the vehicle model is designated as virtual, then for estimation of the purchase price, an identifier of another vehicle that the virtual vehicle is derived from (everything similar except the powertrain) is required as an input.
- Maximum total incentive (in first year equivalent $ amount) for each vehicle.
- Baseline value for the CI of manufacturing the traction battery (in g-CO2/kWh): Since this value depends on the battery chemistry as well as the setup of the battery pack, and could also depend on the supply chain, this input can be separately adjusted for each vehicle model in the set. In this paper, these values are based on industry-wide generic estimates from GREET [33].
- Default/baseline value and variation limits (upper and lower bound) for the adjustable scenario parameters discussed in Section 2.2.1.
- Cost profile scaling curves for the main powertrain components: For example, following the cost estimation model for a gasoline engine system in the NREL model in [39], the default value of $19.81/kW only applies to an engine sized at 100 kW. Downsizing the engine does not proportionally reduce the cost of the engine system because the first-order cost model in [39] includes a constant term of $531. Instead, if a 100 kW engine system costs $1981, a 50 kW engine system costs $1256 (rather than $990.5).
- Charging availability and behavior model: The simulations consider a baseline case where all the plug-in vehicles are fully charged at the beginning of any driving day. Additional simulation options also consider daytime opportunistic charging when the time signature of trips/drive cycles show a break between trips that exceeds some threshold time window. Simulation options can also consider a fraction of the PHEVs not charging at all.
- Charging equipment inputs: this includes the power ratings for Level-1 (L1) and Level-2 (L2) chargers, battery state of charge (SOC) profile when utilizing DC Fast charging, and whether plug-in vehicle owners choose to install L2 charger at home.
- Range anxiety model for BEVs, defined via the profile of a piecewise linear curve for the amount of “spare remaining AER” needed before taking a trip, as a function of the upcoming trip length: For example, the behavior of some owners is simulated as that they would not take a 100-mile trip with their BEV unless the SOC indicator shows 120 miles of remaining range available (i.e., 20 miles to spare). Multiple levels of range anxiety (representing different risk tolerance levels by BEV owners) can also be defined.
- Designation for one or two vehicle models that serve as the “replacement vehicle” for the BEV on days where the BEV AER and planned driving pattern (trip lengths and charging opportunities between trips) would make it fall short of the range anxiety requirements: to limit the complexity of alternative FASTSim simulations that need to be performed, the designated replacement vehicle is restricted from being a plug-in vehicle, i.e., it can only be CICE, HEV or FCEV.
- Set of trips/drive cycles that represent real-world driving: In this paper, all ~65 thousand trips in CHTS [31] are utilized, but other trips/drive cycles could be imported via the GUI of CarGHG. For example, if one wishes to consider more urban or more rural driving patterns, it is plausible to consider partitioning CHTS trips accordingly, such as in [40].
- Hourly profile for marginal GHG emissions in the electric grid [41] and the unit cost of electricity: It is noted that while adjustments to the hourly profile of the electric grid do not require rerunning of the FASTSim simulations, they do require rerunning of the post-processing after FASTSim simulations for event timing optimization (discussed in Section 2.3.4). In this paper, the adopted hourly profile for marginal GHG emissions followed that of the Western US in [41], while the unit cost of electricity was assumed to be time invariant.
- Depreciation model as function of years of ownership and accumulated mileage at the time of vehicle resale: since this can differ between different powertrain types, size category or even brand, the depreciation model can be edited separately for each vehicle in a study set.
- Manufacturing GHG estimates for everything in the vehicle except the traction battery, as well as the expected lifetime miles, further discussed in Section 2.4.2.
- Charging Efficiency: This can be adjusted separately for each plug-in vehicle in the study and can be different by charger type (L1, L2 or DC Fast). For studies in this paper, however, the default value of 86% from FASTSim [26] is adopted for all plug-in vehicles and charger types (i.e., for every 1.0 kWh consumed from the electric grid, energy in the traction battery increases by 0.86 kWh).
- Annual licensing and insurance costs (in $) for each vehicle in the study set.
- Maintenance cost, modeled as an average $/mile for each vehicle in the study set.
- Costs of installing a home charger.
- Cost model for the replacement vehicle for unfulfilled BEV driving days: This could take the form of a flat fee (in $/unfulfilled-day), representing a situation where the replacement is a rental vehicle; distance-based fee (in $/mile), representing a situation where the replacement is a ride share or accumulated mileage on another household vehicle; or a combination of $/unfulfilled-day and $/mile. For studies in this paper, we consider the replacement vehicle being another household vehicle, with the $/mile value estimated from the TCO of the CICE vehicle.
2.3. FASTSim Simulations
2.3.1. Overview of FASTSim
2.3.2. Simulation of Plug-In Hybrids
- For driving days with a total distance (sum of travel distance among all trips within the driving day) less than or equal to the AER of the plug-in hybrid, the simulation proceeds similar to the overnight-only charging behavior (i.e., no daytime charging), as it is assumed that the vehicle owner would not bother seeking to do daytime charging events.
- For driving days with a total distance exceeding the AER but no time gaps between trips of the day that exceed the threshold duration for opportune charging, the simulation proceeds similar to the overnight-only charging behavior.
- For driving days with a total distance exceeding the AER and that have (one or more) time gaps between trips of the day that exceed the threshold duration for opportune charging, the simulation considers a charging event to have occurred during that time gap. The model for a daytime charging event is that it increases the SOC (from its value at the end of the previous trip) in accordance with the charger type (assumed to be L2 for plug-in hybrids; BEVs can have DC Fast) and the amount of time available for charging, or up to SOC = 1.
2.3.3. Simulation of BEVs
- If the total distance for the driving day is less than the AER of the BEV by a margin that satisfies range anxiety for the simulation case, the FASTSim BEV model is simulated with SOC = 1 (fully charged) at the start of the first trip of the day, and no daytime charging events are conducted. For each trip, the travel distance and electricity consumption (in kWh) are recorded, and the corresponding charging event for that drive day is only the one preceding the day (i.e., after the last trip of the previous day).
- If the AER of the BEV is not sufficiently longer than the total distance for the driving day by a margin that satisfies range anxiety for the simulation case, and the simulated charging behavior is overnight-only, then the BEV is assumed to not be utilized for this driving day, and instead, the FASTSim model of the designated replacement vehicle(s) will be simulated, and the corresponding type and amount of fuel is recorded for each trip of that driving day.
- If the AER of the BEV is not sufficiently longer than the total distance for the driving day by a margin that satisfies range anxiety for the simulation case, and the simulated charging behavior considers opportune daytime charging, the capability of the BEV to fulfill the driving day is assessed by considering as many as possible daytime charging events during stops between trips that have a longer duration than the threshold of the daytime opportune charging model. The driving day is considered “BEV fulfillable” if the BEV could complete the driving day with DC Fast charging during the opportune daytime charging events without the SOC falling below the range anxiety limit of the simulation case.
- ▪
- If the driving day is deemed BEV fulfillable, the BEV model is used for the FASTSim simulations, trip distances and electric energy consumption are recorded, and the corresponding charging events time limits are recorded. Though fulfillment of the driving day is based on whether it could be completed with DC Fast charging, if the duration between trips is long enough that the day could be completed with L2 charging, the charging events are flagged as L2 charging.
- ▪
- If the driving day is not deemed BEV fulfillable, FASTSim simulations are conducted for the designated replacement vehicle(s), and the corresponding type and amount of fuel is recorded for each trip of that driving day.
2.3.4. Inferring Charging Event Characteristics
- (i)
- Electric energy delivered to the battery (in kWh);
- (ii)
- Type of charger (L1, L2 or DC Fast);
- (iii)
- Date and time signature for end of the trip prior to the charging event ;
- (iv)
- Date and time signature for start of the trip after the charging event ;
- (v)
- Necessary time duration for completing the charging event () at the modeled charging rate for the charger type, which must be no more (but could be less) than the charging time window of opportunity between and .
2.4. GHG Estimation
2.4.1. Well to Wheels GHG
2.4.2. Lifecycle GHG
2.5. Cost Estimation
3. Results for Select Light-Duty Vehicles
3.1. Select 2016–2017 Model-Year Vehicles
3.2. Select 2022 Model-Year Pickup Trucks
4. Results for Virtual Vehicle Models
4.1. Pickup Trucks
4.2. Different Scenarios for Small SUVs
4.2.1. Baseline Scenario
4.2.2. Sensitivity of LCA GHG and TCO to Scenario Parameters
- The CI of the gasoline blend is the most impactful scenario parameter for LCA GHG of CICEs and HEVs, and is also moderately impactful for PHEVs and only slightly for BEVs. The reason the CI of gasoline has any bearing at all on the GHG of BEVs in this model is an artifact of considering the driving on the replacement CICE vehicle on days where the BEV is unable to fulfill the required driving. Such dependency of the GHG of BEVs on the CI of gasoline gets eliminated in scenarios where 100% of BEVs are utilized for all trips while altering the driving plan to include additional stops if necessary.
- The fraction of non-charging vehicles has a high impact on the LCA GHG of PHEVs as well as their TCO. In fact, in an extreme case where none of the PHEVs are ever charged, the LCA of the PHEV becomes slightly worse than an equivalent HEV due to approximately the same W2W GHG (additional mass from a larger battery than an equivalent HEV is on par with one additional passenger in the car), but there is higher manufacturing GHG for the larger-sized battery. The increased TCO for PHEVs that do not charge stems from low electricity prices compared to gasoline, where PHEVs that do not charge could be missing out on an opportunity for cost savings. However, in scenarios with more expensive electricity prices, the cost advantage of charging PHEVs (and the sensitivity of TCO to charging behavior) diminishes.
- The W2W GHG of electricity is significant for both BEVs (most significant parameter) as well as PHEVs (though not the most significant parameter).
- The manufacturing GHG for everything in the vehicle aside from the traction battery is of some significance to CICEs and HEVs (but not as much as the CI of gasoline), and very significant for PHEVs and BEVs, even more so than the manufacturing GHG for the traction batteries. While this might be somewhat of a surprising finding, especially for BEVs that have large batteries, it is a testament (per the GREET model [33]) that even a BEV has many parts that require many different materials besides the traction battery.
- The cost of the traction batteries is the most significant parameter for the TCO of BEVs and is also significant for PHEVs, while cost of the electric drive (motor) system is secondary (but not trivial) for BEVs, PHEVs and HEVs. The price of electricity for charging also appears secondary (but not trivial) for both BEVs and PHEVs.
- The cost of the gasoline blend is the most significant parameter for the TCO of CICEs and HEVs, and is secondary (but not trivial) for PHEVs.
4.2.3. Simulation of Near-Term and Future Scenarios
5. Discussion
6. Conclusions
Supplementary Materials
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
Abbreviations
| AER | All-Electric Range |
| ANL | Argonne National Laboratory |
| BEV | Battery (only) Electric Vehicle |
| CHTS | California Household Travel Survey |
| CI | Carbon Intensity |
| CICE | Conventional Internal Combustion Engine |
| DC | Direct Current |
| EOL | End of Life |
| FCEV | (Hydrogen) Fuel-Cell (hybrid) Electric Vehicle |
| FSPT | Full-sized Pickup Truck |
| GHG | Greenhouse Gas |
| GUI | Graphical User Interface |
| HEV | Hybrid Electric Vehicle |
| L1 | Level-1 (charger), typically low power, up to 1.5 kW |
| L2 | Level-2 (charger), higher power than L1, typically up to 6 kW to 7 kW |
| LCA | Lifecycle Analysis |
| MSRP | Manufacturer’s suggested retail price |
| NREL | National Renewable Energy Laboratory |
| PFCEV | Plug-in (Hydrogen) Fuel-Cell Electric Vehicle |
| PHEV | Plug-in Hybrid Electric Vehicle |
| RPE | Retail Price Equivalent |
| SOC | State of Charge (for the traction battery) |
| SUV | Sports Utility Vehicle |
| T2W | Tank to Wheels |
| TCO | Total Cost of Ownership |
| W2T | Well to Tank |
| W2W | Well to Wheels |
| Symbols | |
| The following symbols are used in this manuscript: | |
| α | Amount of fuel consumed in a trip |
| β | Amount of electric energy consumed in a trip |
| δ | Optimized amount of time delay for start of charging |
| ε | Amount of electric energy (in kWh) charged or discharged to/from the traction battery |
| ϕ | Normalized W2W GHG (in g-CO2/mile) |
| γ | Fraction of non-charging plug-in hybrids |
| η | Charging efficiency from the grid for a plug-in vehicle |
| λ | CI of fuel (in g-CO2 per unit of fuel) |
| μ | Grid average CI of electricity (in g-CO2/kWh) |
| ν | Sliding scale for interpolation between levels of BEV range anxiety |
| θ | Scaling factor for traction battery manufacturing GHG |
| ρ | Sliding scale between lower and upper bounds for the manufacturing GHG of everything in the vehicle except the traction battery |
| τ | Necessary duration to complete a charging event |
| ψ | Total manufacturing GHG (in g-CO2) for a vehicle |
| ζ | Sliding scale for interpolation between levels of charging behavior |
| Δ | Normalized total cost of ownership for first vehicle owner (in $/mile) |
| Φ | Vehicle model estimated W2W GHG performance (in g-CO2/mile) |
| Γ | Total cost of ownership for first vehicle owner (in $) |
| Λ | Normalized LCA GHG sensitivity |
| Π | Normalized TCO sensitivity |
| Θ | Normalized LCA GHG for a vehicle (in g-CO2/mile) |
| Ω | Price premium scaling for DC Fast charging |
| Ψ | Normalized total manufacturing GHG for a vehicle (in g-CO2/mile) |
| a | Average annual travel distance by vehicle (in miles/year) |
| b | Rated capacity of vehicle traction battery (in kWh) |
| d | Rated power of conventional drive system (in kW) |
| e | Rated power of electric drive system (in kW) |
| h | Hourly curve (relative marginal GHG emissions or relative cost) for the electric grid |
| l | Length (or driving distance) for a trip/drive cycle |
| m | Mass of everything in a vehicle except the traction battery pack |
| n | Number of Years of vehicle ownership |
| p | Purchase tax rate |
| r | RPE for everything in the vehicle except the electrified powertrain |
| s | RPE for the electrified powertrain |
| t | Date and time signature |
| u | Estimated number of BEV unfulfilled driving days per year (in days) |
| v | Estimated fraction of annual miles traveled that are unfulfilled by a BEV |
| w | Demographic weighing factor for a trip/drive cycle |
| C | Function for estimation of the direct cost for a subsystem in the vehicle (type of vehicle subsystem indicated via a subscript) |
| D | Depreciation function for estimating the resale value of a vehicle |
| H | Average scaling factor for GHG or cost of charging, relating the average GHG/cost associated with the timing of charging event(s) relative to the average for the grid |
| L | Expected vehicle lifetime travel distance (in miles) |
| M | Manufacturing GHG CI (per kg-vehicle or per kWh-traction battery) |
| R | Running cost coefficient (type and units of the running cost indicated via a subscript) |
| Subscripts | |
| a | Indicates cost per distance traveled (in $/mile) on alternative vehicle for BEV unfulfilled driving days |
| b | Indicates function for estimation of the direct cost of the traction battery system |
| c | Index for simulated occurrences of charging events |
| d | Indicates function for estimation of the direct cost of the conventional drive system |
| e | With main symbol C, indicates function for estimation of the direct cost of the electric motor system; With main symbol R, indicates unit cost of electricity for charging the vehicle (in $/kWh) |
| g | Indicates unit cost of gasoline (in $/gal) |
| i | Index for simulated trips or drive cycles |
| j | Index for charging behavior model |
| k | Index for BEV range anxiety setting |
| l | Indicates annual licensing fee (in $/year) |
| m | Indicates average insurance cost (in $/mile) |
| o | Indicates estimate of the direct cost of everything else in the vehicle |
| r | Indicates cost per day (in $/day) for BEV unfulfilled driving days |
| s | Indicates annual insurance cost (in $/year) |
| Superscripts | |
| A | Indicates acquisition cost portion of the TCO |
| B | Indicates CI for manufacturing GHG of the traction battery in (in gCO2/kWh-battery) |
| C | Indicates relative cost for hourly curves of the electric grid, cost scaling factor (relative to grid average) for a charging event, or delayed start of charging for minimum cost of a charging event |
| E | Indicates ending time bound for a charging event |
| G | Indicates relative GHG emissions for hourly curves of the electric grid, GHG scaling factor (relative to grid average) for a charging event, or delayed start of charging for minimum GHG of a charging event |
| L | Indicates lower bound for CI of manufacturing GHG for everything in a vehicle except the traction battery pack (in gCO2/kg-vehicle) |
| P | Indicates purchase cost portion of the acquisition cost in the TCO |
| R | Indicates running cost portion of the TCO |
| S | Indicates starting time bound for a charging event |
| U | Indicates upper bound for CI of manufacturing GHG for everything in a vehicle except the traction battery pack (in gCO2/kg-vehicle) |
| V | Indicates resale value and incentives portion of the acquisition cost in the TCO |
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| Scenario Parameter Description | Default Unit |
|---|---|
| Cost model of Gasoline Engine System | $/kW |
| Cost model of Diesel Engine System | $/kW |
| Cost model of Natural Gas Engine System | $/kW |
| Cost model of Hydrogen Fuel Cell System (not including Tank) | $/kW |
| Cost model of Hydrogen Tank | $/kg-H2 |
| Cost model of Electric Motor(s) | $/kW |
| Cost model of Traction Battery | $/kWh |
| Retail Price Equivalent (RPE) | – |
| RPE for Electric Powertrain Components (Battery, Motors,… etc.) | – |
| Vehicle Ownership Time | year |
| Average Annual Driving Distance | mile |
| Average Annual Number of Driving Days | day |
| Fraction of vehicle buyers installing a new home charger | % |
| Sliding scale for equivalent amount of incentive received | % |
| Average price of Gasoline | $/gal |
| Average price of Diesel | $/gal |
| Average price of Natural Gas | $/m3 |
| Average price of Hydrogen | $/kg-H2 |
| Average price of Electricity | $/kWh |
| Electricity price premium for DC Fast Charging | % |
| Average W2W GHG of Gasoline | g-CO2/gal |
| Average W2W GHG of Diesel | g-CO2/gal |
| Average W2W GHG of Natural Gas | g-CO2/m3 |
| Average W2T GHG of Hydrogen | g-CO2/kg-H2 |
| Average W2T GHG of Electricity | g-CO2/kWh |
| Sliding scale for Manufacturing GHG of “Everything Except Battery” | % |
| Sliding scale for Manufacturing GHG of Battery | % |
| Equivalent fraction of PHEVs that do not charge | % |
| Minimum time between trips to consider a charging event | hour |
| Sliding scale for timing of charging events (minimizing charging cost vs. dynamic hourly pricing or minimizing charging GHG) | % |
| Sliding scale for BEV replacement vehicle for days where a BEV range and charging capabilities cannot fulfill the required travel | % |
| Sliding scale for BEV range anxiety | % |
| Scenario Parameter | Scenario | ||||
|---|---|---|---|---|---|
| Web-App Default | Near Term-1 | Near Term-2 | Future Setting-1 | Future Setting-2 | |
| Battery System Cost [$/kWh] | 150 | 150 | 150 | 100 | 90 |
| Motor System Cost [$/kW] | 12 | 12 | 12 | 6 | 6 |
| Battery Mfg. GHG | (Baseline) | 10% Less | 20% Less | 50% Less | 50% Less |
| Rest of Vehicle Mfg. GHG | (Baseline) | (Baseline) | (Baseline) | 30% Less | 30% Less |
| Electricity Price [$/kWh] | 0.12 | 0.3 | 0.3 | 0.3 | 0.3 |
| Gasoline Blend Price [$/gal] | 5 | 5 | 5 | 6 | 8–12 |
| BEV Range Anxiety [miles] | 20 | 20 | – | – | – |
| BEV Charging Behavior | Overnight | Overnight + Daytime | Unlimited | Unlimited | Unlimited |
| PHEV Charging Behavior | Overnight | Overnight w/12% Non-Chg. | Overnight w/12% Non-Chg. | Overnight w/12% Non-Chg. | Overnight w/12% Non-Chg. |
| W2W Electricity GHG [g-CO2/kWh] | 220 | 200 | 180 | 120 | 60 |
| W2W Gasoline Blend GHG [g-CO2/gal] | 10,680 | 10,680 | 10,680 | 10,680 | 6408–4272 |
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© 2026 by the authors. Published by MDPI on behalf of the World Electric Vehicle Association. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license.
Share and Cite
Hamza, K.; Laberteaux, K.; Chu, K.-C.; Benoliel, P. Future Projections of Lifecycle Cost and Greenhouse Gas Emissions of Light-Duty Vehicles. World Electr. Veh. J. 2026, 17, 347. https://doi.org/10.3390/wevj17070347
Hamza K, Laberteaux K, Chu K-C, Benoliel P. Future Projections of Lifecycle Cost and Greenhouse Gas Emissions of Light-Duty Vehicles. World Electric Vehicle Journal. 2026; 17(7):347. https://doi.org/10.3390/wevj17070347
Chicago/Turabian StyleHamza, Karim, Kenneth Laberteaux, Kang-Ching Chu, and Peter Benoliel. 2026. "Future Projections of Lifecycle Cost and Greenhouse Gas Emissions of Light-Duty Vehicles" World Electric Vehicle Journal 17, no. 7: 347. https://doi.org/10.3390/wevj17070347
APA StyleHamza, K., Laberteaux, K., Chu, K.-C., & Benoliel, P. (2026). Future Projections of Lifecycle Cost and Greenhouse Gas Emissions of Light-Duty Vehicles. World Electric Vehicle Journal, 17(7), 347. https://doi.org/10.3390/wevj17070347

