Steel For Fuel N° 014 of 56 3 Apr 2024
How will we move the big, heavy things?
by Andy Lubershane, Partner and Head of Research, Energy Impact Partners
In this note
The question
How will we decarbonize the big, heavy things: trucks, planes, ships and trains?
The answer
Mostly not by picking a winning drivetrain. Lubershane’s stated hypothesis is that the hard part is the hub where these vehicles refuel, not the vehicle, so he expects a lot of electrification where the infrastructure can be built, partial or hybrid approaches where it cannot, hydrogen where demand is concentrated enough to justify a pipeline, and synthetic jet fuel for aviation. He says outright that there are too many uncertainties to predict any single vehicle class with confidence.
03The argument
The post rebuilds the case for electrification in order to mark where it stops. In 2009, when Tesla launched the Roadster, batteries, biofuels and hydrogen all looked roughly equally plausible, and he admits he was carrying a dog-eared copy of a 2002 book on the hydrogen economy at the time. Batteries won light and medium duty vehicles for unglamorous reasons. Biofuels were never scalable enough, already consuming a worrying share of American corn and soybeans with questionable life-cycle benefits. Hydrogen made by electrolysis is inherently a derivative of the clean power that makes it, so it costs more joule for joule once electrolysis equipment and conversion losses are added, and it is awkward to store, move and handle; the grid, meanwhile, already exists. What closed the remaining gap on up-front cost was not a breakthrough but learning curves, roughly a thousandfold increase in manufacturing scale, mostly in China, with just enough product iteration at each new factory to keep improving. He is careful that the learning is done by people, which is why new American battery plants are joint ventures with experienced Asian manufacturers, and why he thinks the gains are fragile: the biggest risk to electric vehicles is now a schism between the Chinese supply chain and Western markets rather than the pace of technology.
So why not the heavy things too? Two constraints. Energy density is the obvious one, and by itself it would only narrow the field: batteries are far heavier and far bulkier than liquid fuel for the same energy, which light vehicles can absorb and weight-, volume- and range-constrained ones cannot. The second constraint is the one the post is really about, and it sits off the vehicle entirely. Trucks are the near case, and he is explicit that one more leap in battery technology would probably make the vast majority of them viable targets. Most freight trips are already short enough to electrify, but the minority of long trips carries most of the ton-miles, and sizing a truck’s battery for the worst trip it might face implies a charger several times more powerful than today’s fastest, which he notes are rated at less than a fifth of what would be needed. A depot or rest stop full of those draws power like a small city. Aviation makes the point harder still: by his own calculation a single hybridized mid-sized plane charging at one gate would double a small airport’s peak demand, and a study he cites finds that electrifying only the ground equipment and rental cars would roughly quintuple an airport’s peak. At the Port of Long Beach, four of the ten years a cargo-handling electrification project took were the utility building new transmission and substations, and that was before anyone considered a tugboat. Each case is also a chicken-and-egg problem, because operators will not commit to electric fleets until fast charging exists away from the depot, while utilities struggle to win regulatory approval for infrastructure without a clear demand signal.
That is why the argument turns back toward molecules, and the turn rests on scale rather than chemistry. For an ordinary filling station, building hydrogen delivery from scratch is more daunting than upgrading the wires. At a port or a large airport the sheer concentration of demand can level that comparison or tip it, because moving very large quantities of energy as a gas through a pipeline is usually cheaper than moving it as current through a transmission line. Trains fit the pattern best, shuttling between two depots, and three European manufacturers have already launched hydrogen models. Hydrogen still buys range at the cost of volume, so most hydrogen vehicles have to be redesigned from a clean sheet, and he notes that practically nobody is attempting it for cargo ships. Upgrading hydrogen into denser liquids, the category he calls electrofuels, trades further cost for density: ammonia and methanol compete for shipping, while aviation converges on synthetic jet fuel precisely because it changes nothing. It will cost several times its fossil namesake to produce, but it needs no new aircraft, no new operations and no new fuel infrastructure, and he thinks that alone could make it a commercial winner.
He closes by raising an objection he does not answer. A genuinely net-zero synthetic hydrocarbon needs its carbon pulled from the air, and if direct air capture ever becomes cheap enough to supply it, he suggests $200 a ton or less, then the same capture could simply be buried while the world keeps burning fossil fuel, for the same net carbon balance. He says he has wrestled with this since he first encountered the concept, and defers it to the final instalment of his series. What he will commit to is the hub: building the energy infrastructure to serve truck stops, airports and ports will probably be a bigger challenge than designing an entirely new truck, ship or plane.
04What you need to know first
- Gravimetric and volumetric energy density
- How much energy a fuel or battery holds per kilogram and per unit of space. Heavy vehicles are usually short of both at once.
- Ton-miles
- Freight weight multiplied by the distance it travels, which is not the same measure as counting trips and does not rank them the same way.
- Electrofuels
- Liquid fuels made by upgrading clean hydrogen into denser molecules such as ammonia, methanol or jet fuel, using processes themselves run mostly on clean electricity.
- Direct air capture
- Pulling carbon dioxide back out of the atmosphere. It is the carbon source that would make a synthetic hydrocarbon net-zero, and the reason the post’s closing question exists at all.
05Details worth keeping
- The post opens with three photographs rather than an argument: the Iowa 80 truck stop, Hartsfield-Jackson airport, and the neighbouring ports of Los Angeles and Long Beach, which he asks the reader to keep in mind throughout.
- He is drawn to partial electrification as a way around megawatt charging, naming Range Energy’s electrified tractors, which he describes as designed to partially pull themselves, and Revoy’s driverless secondary tractors that sit between tractor and trailer and swap themselves out at charging stations.
- Cape Air’s letter of intent for 75 electric commuter aircraft from Eviation is offered as genuinely interesting and explicitly not as a first step toward larger planes or longer flights.
- ZeroAvia and Universal Hydrogen are named as the few companies pioneering hydrogen aviation.
- On shipping fuels he reports a live internal disagreement at his firm between “Team Ammonia” and “Team Methanol”: net-zero ammonia is cheaper to produce because net-zero methanol needs captured carbon, but ammonia is far more toxic, which raises delivery and storage costs both in ports and on ships.
- He names Metafuels, a portfolio company at his firm, in passing as working on a more efficient methanol-to-jet-fuel pathway.
- Several figures carry evidence the prose does not restate: the two uncaptioned images comparing the space fuel oil and an equivalent battery would occupy on a container ship, the chart of the power needed by the roughly 1,600 drayage trucks based at the Port of Long Beach, and the diagram of the synthetic jet fuel process. The note cannot reproduce them.
06Claims worth citing
All figures as stated on 2024-04-03. Charger ratings, battery density targets and fuel cost multiples move quickly and should be read as a snapshot.
- Batteries are currently around two orders of magnitude heavier than liquid hydrocarbons, need nearly twenty times as much space as a diesel tank for the same energy, and twice as much space as compressed hydrogen. Lubershane
- The vast majority of freight shipments are under 250 miles, already in scope for a few first-generation electric semi-trucks, but the smaller number of longer trips accounts for the majority of total ton-miles. Lubershane, with a chart credited to the DOE Vehicle Technologies Office
- To cover half the distance a typical long-haul truck travels between breaks, a fully electric truck would need about a megawatt-hour of battery, equivalent to 10 to 15 light duty EV batteries, and a two megawatt charger for a thirty-minute turnaround; today’s “ultra” fast chargers are typically rated at 350 to 375 kilowatts. Lubershane
- An analysis of around 70 prospective charging sites in New York and Massachusetts stands as his evidence for the grid scale involved. Its numbers sit only in the figure, and the post dates it twice: the prose calls it the electric utility National Grid’s landmark 2021 “Electric Highways” study, while the figure credits National Grid, RMI, Stable and Geotab and dates it Nov 2022. National Grid and partners, cited by Lubershane
- Electrification is currently viable only for a tiny sliver of air traffic served by very small planes, and even a doubling of battery gravimetric density would leave it impossible for the vast majority of flight-miles. International Council on Clean Transportation, cited by Lubershane
- An average mid-sized 100-ton plane would need about five megawatt-hours of battery to fly electric for 100 miles of a typical 500-mile flight; charging that in half an hour means a 10 megawatt connection, so one hybrid plane at one gate would double a small airport’s peak demand, and hybridizing a mid-sized airport’s fleet would need new supply on the order of a nuclear power plant. Lubershane’s own calculation, labelled as such
- Electrifying ground-based equipment and rental vehicles alone, setting the planes aside, would roughly quintuple peak electricity demand at two representative airports, Minneapolis and Denver. Enterprise Mobility with Xcel Energy and Jacobs, cited by Lubershane
- Aviation fuel derived from biomass could satisfy only about half the aviation industry’s needs. (A 2021 conclusion Lubershane attributes in the text to the “Air Transport Group”; the accompanying figure credits the Air Transport Action Group’s “Waypoint 2050”)
- A ten-year project begun in 2011 at the Port of Long Beach electrified 18 ship-to-shore cranes, 5 intermodal cranes and 70 yard gantry cranes and brought shore power to one of seven major cargo terminals; four of those ten years were the utility building a 66 kV subtransmission line and four new substations. (Lubershane, who believes it was the largest port electrification project of its kind to date)
- Synthetic jet fuel will probably cost three or four times fossil jet fuel to produce, on par with the most expensive biofuels. Lubershane
- Hydrogen stores about twice as much energy in a given volume as a lithium-ion battery pack, still nowhere near a hydrocarbon, while being the most gravimetrically dense transport fuel and refuelling nearly as fast as diesel. Lubershane
- A chart behind his claim that battery electric vehicles tend to be the cheapest to operate, including against fossil fuel vehicles, is sourced to his own firm’s analysis and assumes delivered hydrogen at $5 per kilogram and industrial electricity at $0.15 per kilowatt-hour. EIP analysis, presented by Lubershane
07Where it’s contested
Nobody argues back. This is one person working through a question he labels a current hypothesis at the top and calls unresolved at the end.
- He marks his confidence unevenly and deliberately. He is bullish on electrification in the “long, long, long term” while arguing we should be realistic about the next couple of decades, and he says he is a big fan of partial electrification while only suspecting it could beat fully electric tractors, rather than showing it.
- He revises himself in public. On ammonia versus methanol for shipping he says he has switched sides twice.
- The largest question is raised and deferred. If direct air capture gets cheap enough to supply synthetic fuels, burying that carbon while burning fossil fuel yields the same net balance for less work. He explicitly punts the answer to the final instalment of his series, so the case for electrofuels here rests on a question the post does not resolve.
- A load-bearing premise is imported rather than defended. That the grid cannot be expanded at the pace required is carried over from his own earlier argument about an “Electricity Gauntlet” and asserted here rather than established.
- Some of the evidence sits in images. The maritime case in particular is argued by figures rather than in prose, so a reader accepting it is accepting a picture.
- What he has at stake. He is a working investor in this sector. The one portfolio company he names, Metafuels, is disclosed inline as an investment of his firm, and the operating-cost comparison is his firm’s own analysis on its own stated assumptions.