Economic optimization analysis of different electric powertrain technologies for vans applied to last mile delivery fleets

Freight transport companies are facing new challenges linked to sustainability, energy efficiency, and cost optimization issues in the urban distribution of goods. In this sense, battery electric vehicles (BEVs) will help in reaching sustainability targets due to their local cero emissions and lesser expensive operational costs than fossil fuel vans. However, shortly other electric powertrain technologies will be available, such as hydrogen fuel cell vehicles (FCEVs) and range extender hybrid electric/hydrogen fuel cell vehicles (FC-EREVs). Depending on the powertrain typology, electric vans present operational limitations related to range, recharging time, recharging infrastructure, and the lack of experience in the powertrain performance or economic feasibility. The variety of available powertrain options and the operational uncertainties urge the development of tools to assist fleet managers in vehicle replacement decisions. In this research work, it has been developed an optimization model to assess the influence of several operational and economic aspects of van fleets within the framework of the Spanish market, taking into account the powertrain technologies available and their related infrastructure to shape the cost-optimal van fleet composition in an established period and the associated cost breakdown. This research determines the key operational and economic variables from the cost per kilometer point of view where a certain van type becomes competitive compared to the other options. The results indicate that FC-EREV vans using purchased hydrogen delivered at the depot are the best option in a wide range of economic and operational conditions. Additionally, considering onsite hydrogen production via electrolysis using the grid, the BEV van is the preferred vehicle, but FC-EREV could be a suitable option for limited yearly distances (up to 25.000 km/year) and hydrogen purchase costs over 4,2 €/kg.