Try2B Comprehensive: Your numbers are still off. First of all, a gallon of diesel has 11% more energy than a gallon of gas. Second, a diesel engine has higher thermal efficiency than a gas engine - googling around seems to indicate that big diesel truck engines are around 42% efficient, and there are initiatives to raise that over 50%, such as going to turbodiesels. The DOE is setting 50-55% brake thermal efficiency targets for 2016.
Second, that heat energy is not all lost. Some of it goes to heating the vehicle.
So a gallon of diesel has 37.95 kwh of energy. If the truck engine is 42% efficient and the truck requires 200 gallons to go 1000 miles, It’s using 3187 kwh of energy, or roughly 16 kwh per mile.
Our Tesla battery weighs 550 kg and contains 90 kwh of energy. But not all that energy is usable - to keep a lithium ion battery healthy and to operate it safely, you can’t let the voltage go higher or lower than its nominal operating range. In practice I believe only about 80% of the total charge is usable. So, that’s now 72kwh. And since we’re adding engine efficiency into the mix, we have to multiple by the efficiency of the electric motor - call it 90%. So, we get 65 kwh of usable power for 550kg, or about 8.5kg/kwh. We’re back up to 27,000 kg of battery for our trip.
And this is the best we can hope for. Once you get into the real world, all these numbers get worse. For example, the battery will self-discharge at a rate of about 8% per month at 20 degrees C. That might not cost a lot in range per trip, but it adds 8% per month to your energy cost. In addition, the battery may need to be heated and cooled to maintain optimum performance. At 60C, a li-ion battery discharges at a rate of 31% per month. In cold weather its performance degrades and it can’t hold a charge as long - you can lose as much as 50% of the battery’s charge capacity in cold weather - or you can heat it. But that also takes energy.
Better take into account the cooling requirements or greatly increase the volume requirements for your battery, too. You can’t just stack tesla batteries together, because the cube-square problem gets you. Even the Tesla battery requires liquid cooling to keep it from overheating. So you’re going to need a system like that, and a big-ass radiator, which then cuts into your aerodynamics.
I hope this doesn’t sound pedantic, but this stuff always sounds so simple and logical on paper, while an engineer will tell you that the devil lurks in a thousand different details. All of the details tend to work against EV power, which is why it’s so hard to do even in a tiny, highly aerodynamic passenger vehicle.
As for cost savings - 200 gallons of diesel costs you maybe $700. If you can get your electric power for 4c per kwh (which would be at the absolute low end of the scale), that would be $127. But wait - your charger is only about 70% efficient. So that’s $182. Now add in 8-10% for self-discharge losses, And you’re at about $200. We also have to calculate the energy cost of hauling the weight of the batteries and the aerodynamic loss for the radiator needed to cool them, the number of extra trips required to haul a similar amount of cargo because of space reduction, etc. The electricity cost will probably still come in lower than the cost of diesel, but the electricity for damned sure isn’t free.
One way to look at it is if 30% of our cargo capacity is taken up by batteries, the cost per kg of freight hauled also goes up by 30%. So now our $200 energy cost is suddenly $260 - but everything else also goes up by 30% - maintenance, driver wages, road taxes, capital costs for a fleet that can haul the same capacity, etc. And we haven’t even started to talk about the additional cost of all the batteries and gear required to move to electric.
Then there’s cycle durability - I think we the best we can do for li-ion right now is about 1200 full charge cycles before they need to be replaced. And charge capacity starts to drop once the battery is in use, so a mid-life battery isn’t going to have anywhere near the range of a new one. So you need to factor that into your calculations as well. And if you’re parking your big truck outside in a cold area, be prepared to heat your battery continuously, as cold temperatures can really lower their lifespan. So can heat, so if you’re running in a hot area be prepared to keep your battery cool when not in use.
All of this increases effort and maintenance costs on top of the energy costs. Then there are entire questions about the use of these batteries in heavy-duty industrial operations instead of the comparatively light-duty use in a passenger car.
Engineering is all about the details. Things that can look reasonable or feasible in a simple back-of-the-envelope calculation which we’re all doing here can become total non-feasible once real-world constraints are applied and all the little gotchas are taken care of. Vibration will be an issue. Safety is a big issue. 27,000 kg of batteries catching file is a pretty dangerous event.
I did some searching today about new truck technologies for energy efficiency, and I can’t find anyone talking about all-electric tractor-trailer units. Hybrid, yes. Battery-assist, yes. New engine technologies? Yes. But all electric is a non-starter.