Techno-Economic Optimization and Life Cycle Assessment of Heavy-Duty Truck Electrification for Regional Logistics

Background: Road transport accounts for 73% of transport-related greenhouse gas emissions within the EU, 27% of which are attributable to heavy-duty vehicles. In order to reduce emissions in the area of heavy-duty commercial vehicles, electrifying the fleet offers a perspective. As part of a cooperation between TU Berlin, Siemens and BLG Logistics within the Mobility2Grid research campus, an analysis was carried out to determine how an exemplary BLG depot for regional logistics transport with six diesel trucks can be converted to battery–electric trucks. Methods: This analysis was conducted under a fixed depot schedule with defined dwell times and charging opportunities, with the aim of developing practical recommendations for the acquisition of suitable vehicles and infrastructure. To this end, simulations were carried out using the eFlips consumption and depot simulation software developed at TU Berlin. Results and Conclusions The results show that electrification for regional logistics transport can already be fully implemented with the current state of the art technology and that neither very large batteries nor very high charging powers are required for technically feasible and economically balanced operation. Notably, the cost-optimal battery capacities identified (approximately 200–230 kWh) are currently smaller than those of commercially available 40 t electric trucks, revealing a gap between the model-optimal configuration and present market offerings. Based on the identified optimal configuration, a life cycle assessment (LCA) is conducted to evaluate the environmental impact of fleet electrification. Over a 10-year lifetime, the battery–electric fleet reduces cumulative greenhouse gas emissions by approximately 53% compared to the diesel baseline, with operational-phase savings clearly outweighing higher production-related emissions. The combined techno-economic and environmental assessment provides a structured decision basis for depot-centered fleet electrification.