Field notes The Energy Transition for the Rest of Us

Catalyst N° 025 of 125 30 May 2024

Heavy duty decarbonization

with Andy Lubershane, partner and head of research, Energy Impact Partners

In this note
  1. 01The question
  2. 02The answer
  3. 03The argument
  4. 04What you need to know first
  5. 05Details worth keeping
  6. 06Claims worth citing
  7. 07Where it’s contested

The question

Batteries cannot move the biggest, heaviest things. So what fuels the trucks, ships and planes, and what actually decides the answer?

The answer

A three-step ranking: electrify whatever you can, fill the next gap with second-generation biofuels, and use hydrogen derivatives for what remains, which is mostly aviation and shipping. But the thing that decides it is not the fuel’s cost. It is how expensive and disruptive it would be to replace long-lived vehicles and, above all, the hubs they fuel at, which can make a very expensive drop-in fuel the rational choice.

03The argument

Start by presuming electrification and forcing yourself to justify any departure, for two compounding reasons. Clean electricity is cheap as an energy input, and Lubershane expects it to stay cost-effective against biofuels, clean hydrogen and electrofuels even as power prices rise over the coming decades. On top of that, a battery electric drivetrain reaches something like 80% efficiency from electricity into the vehicle to motion, better than any alternative including hydrogen fuel cells. Two things then constrain it. The obvious one is energy density: a lithium-ion battery holds a couple of megajoules per liter where gasoline and diesel hold around 35, and the gap by weight is worse still, with fossil fuels at 45 to 50 megajoules per kilogram. The interesting move is what Lubershane does with the expectation of progress. He thinks it reasonably safe to assume at least a 50% density improvement for high-performance lithium-ion within five to ten years, that doubling is not crazy and tripling is theoretically possible over a longer arc, with the caveat that gains now appear to cost either money or charging speed. And then the point: even a two- to threefold improvement leaves batteries at an enormous disadvantage. Improvement does not rescue the hardest cases, so the density argument holds because of optimism about batteries rather than in spite of it.

The second constraint gets less attention and in some places binds harder, which is the power needed to charge things. Lubershane’s example inverts the intuition the density discussion builds. Drayage trucks at a port are close to the ideal electrification candidate, with short repetitive trips, heavy stop-and-go duty that batteries handle well and no meaningful range problem, and the Port of Long Beach has roughly 1,600 of them. Charge those slowly overnight at 100 kilowatts each and you have still created about 1.6 gigawatts of new peak demand concentrated around the port, which the port’s own study translates into adding 90 megawatts to every existing substation in the area if you had to stay within the current footprint. That is multiple transmission lines’ worth of power into one of the densest operational environments there is. The precedent he cites fixes the timescale: a project begun in 2011 to electrify cargo handling equipment and provide shore power to docked ships took a decade and required Southern California Edison to build a new 66-kilovolt line and four new substations. So a vehicle can be technically and economically viable while the place it refuels is not, and no better battery fixes that.

Mapping both constraints onto modes gives the ranking. Aviation is where density binds hardest, since flight has always been a fight against weight and volume, and Lubershane effectively rules out electrification almost entirely, allowing only very small short-hop aircraft that he calls meaningless for total aviation emissions. Shipping he calls less of an outright no-go, and there the binding measure is volumetric rather than gravimetric, because space consumed by batteries is cargo you do not get paid to carry. Ground transport is the opposite case: he sees a plausible path to high, though not necessarily complete, electrification of even Class 8 trucks over the coming decades, with heavy off-road and mining equipment a possible exception. His preferred bridge there is partial electrification, including battery swapping, which he argues solves three problems at once. A smaller battery costs less range and payload; swapping refuels nearly as fast as diesel rather than the 15 to 30 minutes fast charging optimistically needs; and the removed battery can charge slowly instead of demanding the roughly 8 megawatts that filling a 2-megawatt-hour truck battery in 15 minutes would take. He is candid that he is a sucker for the idea, and Kann supplies the objection he does not answer.

For what electrification cannot reach, biofuels come before hydrogen, because they are already in use at scale and their ceiling is visible. About 40% of the US corn crop already goes to ethanol and roughly 30% of soy to biodiesel, which Lubershane reads as close to tapped out, and the lifecycle benefit of those first-generation fuels is only 25% to 40% against fossil fuel, which he thinks fairly raises whether the food-crop tradeoff is worth it. Second-generation cellulosic feedstocks are more abundant with better carbon intensity, and he argues that is where the transport market should go first, while conceding that maxing out that resource globally and directing all of it to aviation would still solve only about half of aviation’s problem given expected demand growth. Hydrogen and its derivatives are therefore step three. Hydrogen beats fossil fuels by weight and loses badly by volume, only about two to three times better than a battery, so it still forces vehicle redesign, which is why he expects the answer to be upgrading hydrogen into denser molecules by adding carbon, ultimately captured from the air. That is the most expensive route available, since you pay for clean hydrogen, for carbon capture and for the synthesis. His conclusion is that paying it can still be correct, and here the episode turns on itself. If the real constraint is replacing long-lived vehicles and rebuilding hubs that cannot stop operating, then a drop-in synthetic fuel that requires changing neither is worth a large premium. Kann frames the hub as cutting both ways: concentrated enough that fixing it fixes most of the market, and far harder to change than adding chargers house by house.

04What you need to know first

Volumetric versus gravimetric energy density
Energy per unit of space versus energy per unit of weight. Which one binds depends on the vehicle: planes care about both, ships mostly about space because space is cargo revenue, trucks mostly about weight because weight is payload.
Drayage trucks
The short-haul trucks shuttling containers between a port and nearby yards. Their duty cycle makes them the easiest heavy trucks to electrify, which is what makes the port example pointed.
Second-generation (cellulosic) biofuels
Fuel made from woody or fibrous plant material rather than food crops such as corn starch or soy. More abundant and better on carbon intensity, but not yet cheap at scale.
Electrofuels
Clean hydrogen combined with captured carbon to build synthetic hydrocarbons. The appeal is that they are drop-in replacements, chemically the same as today’s jet or shipping fuel, so nothing about the vehicle or the hub has to change.

05Details worth keeping

  • Two named partial-electrification companies: Revoy, which he credits with a clever take on battery swapping for semi trucks, and Range, which makes an electrified trailer that does not try to cover every mile. Both are ways to capture carbon savings without fully electrifying a vehicle up front.
  • Kann’s reference point for the density ceiling is ARPA-E’s PROPEL-1K program, a moonshot target of 1,000 watt-hours per kilogram, which he converts to 3.6 megajoules and calls roughly a tenth of fossil fuel. He warns his numbers may be slightly off, and the transcript garbles his second unit.
  • Methanol is his example of why hydrogen derivatives need carbon: a carbon-neutral methanol needs a carbon atom, probably from captured carbon and ultimately from direct air capture.
  • His case that hubs are the real obstacle is experiential. He has flown through LaGuardia for seven years during a large project to upgrade one terminal, and estimates that electrifying the airport or adding hydrogen fueling would be 10 to 100 times that disruption, in an operation that cannot stop.

06Claims worth citing

All figures as stated on 2024-05-30. Battery density figures, feedstock shares and infrastructure estimates move; treat these as a mid-2024 snapshot.

  • Battery electric drivetrains can reach roughly 80% efficiency from electricity input to motion, higher than any alternative including hydrogen fuel cells. Lubershane
  • Lithium-ion volumetric density of a couple of megajoules per liter against roughly 35 for gasoline and diesel; fossil fuel gravimetric density of 45 to 50 megajoules per kilogram, with the battery figure left out because he declines to do the arithmetic aloud. Lubershane, prompted by Kann
  • At least a 50% improvement in high-performance lithium-ion density is reasonably safe to assume within five to ten years; doubling is not crazy and tripling is theoretically possible, though not necessarily on that timeline. Density gains may now cost either money or charging speed. Lubershane
  • ARPA-E’s PROPEL-1K moonshot of 1,000 watt-hours per kilogram equals 3.6 megajoules per kilogram, roughly a tenth of fossil fuel, with Kann flagging his own numbers as possibly slightly off. Kann
  • The Port of Long Beach is served by about 1,600 drayage trucks; charging them overnight at 100 kilowatts each implies about 1.6 gigawatts of new peak demand within roughly 50 miles of the port. The gigawatt figure is scenario arithmetic, not a measured value. Lubershane, on Port of Long Beach data
  • Accommodating that within the existing substation footprint would mean adding 90 megawatts to every substation in the area, which he calls infeasible. Port of Long Beach study, cited by Lubershane
  • A port electrification effort begun in 2011 covering cargo handling equipment and shore power took ten years and required Southern California Edison to build a new 66-kilovolt transmission line and four new substations. The transcript is ambiguous about whether the shore power portion covered one of the port’s seven major cargo terminals or more. Lubershane
  • Fast charging takes optimistically 15 to 30 minutes at best against a couple of minutes for diesel, and a 2-megawatt-hour semi truck battery charged in 15 minutes would need about 8 megawatts of charging capacity, which he says does not exist today. Lubershane
  • About 40% of the US corn crop goes to ethanol and approaching 30% of soy to biodiesel; corn ethanol is about 10% of gasoline, essentially by law. Lubershane
  • First-generation biofuels show a carbon intensity benefit of roughly 25% to 40% against fossil fuel in most studies, with no specific study named. Lubershane
  • Maxing out second-generation biomass globally and directing all of it to aviation fuel would solve only about half of aviation’s problem, given expected growth in aviation fuel demand. Presented as an optimistic case. Lubershane
  • Hydrogen has better gravimetric energy density than fossil fuels and worse volumetric density, roughly two times better than lithium batteries for compressed hydrogen and up to three times for liquid. He also calls it only “a little bit better” than batteries in the same passage, so the range is loosely stated. Lubershane

07Where it’s contested

  • Battery swapping is where the host pushes back and gets no answer. Lubershane opens by admitting he is a sucker for it and does not know why. Kann objects that nobody has made it work at scale outside China, where NIO runs a large network, and that the West was burned by Better Place in the 2000s. Lubershane answers with a joke, so treat his enthusiasm as a stated preference rather than a defended position.
  • The mode rulings carry hedges that matter. Aviation is “effectively” ruled out “almost entirely,” excepting very small short-hop aircraft he judges immaterial to emissions. Shipping is “pretty much” ruled out, excepting small ships and some ferries, and he explicitly calls it less of a no-go than aviation. Ground transport gets “maybe not 100% electrification, but pretty high levels” over decades, with mining and off-road equipment flagged as possible exceptions.
  • The density forecasts are labeled assumptions. The 50% figure is what he considers reasonably safe to assume; doubling is not crazy; tripling is theoretically possible. Each step carries more hedging and the larger gains have no firm timeline.
  • The headline framing is about fuels; the conclusion is about hubs. Kann’s opening sets the episode up as picking a fuel of choice per mode. Lubershane runs the other way: vehicle and hub turnover is the biggest constraint, and that is what can make an expensive drop-in fuel rational. The fuel is not chosen on its own cost.
  • The biofuel tradeoff is raised, not resolved. He asks whether a 25% to 40% benefit justifies using corn and soy that could be food, then moves to second-generation feedstocks without answering. On which sector should get scarce biofuel he would let the market decide, noting airlines pay the most.
  • In-house conversation with a named investment. Lubershane is Kann’s partner at EIP, and the cost-effectiveness claim for Terragia’s cellulosic ethanol is his own firm’s thesis about a company that has not shown it at scale. Treat it as a design target rather than a measured result.

Cite as: “Heavy duty decarbonization,” The Energy Transition for the Rest of Us, note on Catalyst with Shayle Kann, May 30, 2024. CC BY 4.0. View the Markdown