DHL and Scania Test Electric Semi with Onboard Fuel for Better Range

Scania and DHL to Test an Electric Semi with a Fuel-Powered Range Extender

Scania and DHL Group are working together to test a new electric semi truck. This truck includes a fuel-powered range extender. The goal is to help trucking companies switch to electric vehicles while avoiding common challenges. These challenges include a lack of charging stations and limits on the power grid.

The new truck, called an Extended Range Electric Vehicle (EREV), will be tested between Berlin and Hamburg. DHL’s Post & Parcel Germany division will operate it starting in February 2025. The test will evaluate how well the truck performs in daily operations. If successful, DHL may add more of these trucks to its fleet.

Helping with Charging and Energy Problems

Electric trucks are seen as a key part of reducing carbon emissions. However, many obstacles slow down their adoption. These include:

• Few Charging Stations: There are not enough fast-charging stations for large trucks. Most existing stations are built for passenger cars.
• Power Grid Issues: The electricity grid may not always provide enough power for a large number of electric trucks. Upgrades are needed, but they are expensive and take time.
• High Electricity Prices: During peak hours or bad weather, electricity costs can rise sharply. This makes running an electric truck more expensive at certain times.

The EREV helps solve these issues. It is mainly powered by a battery but also has a fuel-powered generator. This generator provides extra power when needed. As a result, the truck can still run even when charging stations are not available. DHL expects the truck to run on renewable electricity for 80–90% of its trips.

Electric Semi Design and Performance

The EREV is built to balance efficiency and sustainability. Some key details include:

• Size and Capacity: The truck is 10.5 meters long and can carry around 1,000 parcels. It can also pull a trailer for additional cargo.
• Power Source: A 230kW electric motor powers the truck. It can reach a peak of 295kW. The battery has a capacity of 416 kWh.
• Fuel-Powered Range Extender: A 120kW generator provides backup energy. It will first run on petrol but may later use diesel or hydrotreated vegetable oil (HVO).
• Range: The truck is expected to travel between 650 and 800 kilometers before needing a charge or refuel. This is longer than Scania’s fully electric truck, which has a range of about 550 kilometers.
• Top Speed: The vehicle can reach a maximum speed of 89 km/h.

This setup allows the truck to operate mostly on electricity. However, the generator ensures that it can complete long routes if needed.

The High Costs of Electric Semi Trucks

One of the biggest obstacles to electric trucking is cost. Electric trucks cost more than diesel trucks. This is mainly due to:

• Expensive Batteries: Batteries are the most costly part of an electric truck. While prices are falling, they are still a major expense.
• Charging Infrastructure: Companies must invest in charging stations at their facilities. These stations also require power grid upgrades.
• High Upfront Costs: An electric truck can cost nearly twice as much as a diesel truck. However, lower fuel and maintenance costs may help balance this over time.
• Government Support: Many trucking companies rely on grants and tax incentives to make electric truck adoption more affordable.

The EREV provides a middle-ground solution. It offers environmental benefits while reducing the need for large infrastructure investments right away.

Challenges with Electric Semi Charging Infrastructure

For electric trucks to succeed, more charging stations are needed. Right now, there are many challenges:

• Lack of High-Power Charging: Most chargers today are designed for small electric vehicles, not large trucks.
• Slow Charging Speeds: Even fast chargers take longer to charge a truck than it takes to refuel a diesel vehicle.
• Uneven Distribution: Some areas have plenty of charging stations, while others have none.
• Private vs. Public Charging: Some companies invest in private depot chargers. But trucks on long-haul routes need a better public charging network.

These issues make it difficult for trucking companies to switch fully to electric vehicles. That is why solutions like the EREV, which combines battery power with a generator, can help during this transition period.

Policy Considerations and Future Impact

Scania and DHL believe that hybrid-electric solutions like the EREV should be encouraged. They suggest that governments should:

• Offer incentives for hybrid-electric trucks that reduce emissions.
• Adjust road toll pricing to reflect the lower emissions of EREV trucks.
• Support infrastructure projects that expand charging networks.

The first test of the EREV will take place between Berlin and Hamburg. If the results are positive, more trucks could be added to DHL’s fleet. The test will provide valuable information on how hybrid-electric trucks perform in real-world conditions.

Looking Ahead

Scania and DHL are attempting to take a practical approach to the challenges of electric trucking. The EREV truck offers a potential way to reduce emissions without waiting for charging infrastructure to catch up. This project could help speed up a transition to cleaner freight transport.

As the trucking industry moves forward, solutions like the EREV could play a key role. They could allow companies to reduce environmental impact while ensuring that logistics operations remain efficient and cost-effective.

RELATED: True Cost of the Electric Truck: Ryder’s New Analysis, Trump EPA Announcing Reevaluation of the Clean Trucks Plan, US Army Now Testing Autonomous Trucks with DTES Tech