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Presented by Mark Kuhn Principal at Ricardo Strategic Consulting at NAFA 2013
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Ricardo total cost of ownership-economics of emerging fleet technologies
1.
www.ricardo.com © Ricardo plc
2013 Total Cost of Ownership: Economics of Emerging Fleet Technologies NAFA Conference April 25, 2013 Kenworth HEV Bucket Truck Mark Kuhn Principal Ricardo Strategic Consulting Diesel NG EV Diesel HEV NG HEV
2.
© Ricardo plc
2013 2RD.12/272601.5 Contents Scope of study Technologies/segments Analysis methodology Analysis results – Diesel vs. NG, Diesel HEV, NG HEV, EV Conclusions / next steps
3.
© Ricardo plc
2013 3RD.12/272601.5 Model Summary – Included Technologies and Segments Six technologies and 22 technology vehicle segment combinations were included in the model CV Market: Based on Project Segments
4.
© Ricardo plc
2013 4RD.12/272601.5 Representative vehicles were selected to characterize each fleet segment and each technology Baseline Diesel Vehicle Inputs – Representative Vehicles Source: U-Haul, Kenworth of Florida, HT&T Truck Centre, Rock& Dirt, Peterbilt, Kenworth, Ford, NREL, Fleet Equipment Magazine, TRB, Calstart Diesel HEV reference: HEV Express Cargo Van with Duramax 6.6L V8 Turbo Diesel with 260 hp, 525 lb.-ft. torque and B20-Diesel compatibility
5.
© Ricardo plc
2013 5RD.12/272601.5 Vehicle TCO is modeled as the PV of the sum of both CAPEX and OPEX for that vehicle within its first ownership period Vehicle TCO Maintenance Cost Model Summary – Model Structure Vehicle OPEX (PV over vehicle life) Vehicle CAPEX Vehicle Purchase Cost Per Vehicle Infrastructure Cost* Fuel Cost Engine Transmission Brakes Emission Control Installation Permits PV of Maintenance Fuel Consumption Fuel Price Purchase Price Incentives PV of Salvage Proportional Use of Capacity Total Infrastructure Cost Vehicle Fuel Consumption Total Capacity Fuel Economy Idle Time Driving Distance + + x x + * Infrastructure costs assumed to be $0 for diesel
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© Ricardo plc
2013 6RD.12/272601.5 Vehicle level TCO and Payback Periods vary with each vehicle class and duty cycle combination: NG best for Class 3 vehicles; Diesel for Class 8 trucks Model Summary – Vehicle TCO Output TCO Summary Table Source: Diesel Tab 2012 2015 2020 2012 2015 2020 2012 2015 2020 2012 2015 2020 2012 2015 2020 Per Vehicle OPEX $ Diesel 39,864 41,774 46,354 91,556 95,282 105,687 156,911 158,043 168,206 163,600 171,119 192,759 251,418 250,992 263,456 Natural Gas 29,765 33,342 36,625 69,274 77,762 85,333 115,637 127,720 134,810 131,327 148,501 165,576 186,266 199,232 205,072 Electric 12,480 12,938 14,601 58,524 57,645 59,488 3,932 4,064 4,593 2,208 2,275 2,559 6,446 6,726 7,719 HEV 37,067 37,252 39,284 80,351 76,143 80,092 137,160 130,611 131,202 51,730 76,143 1,409 231,651 224,555 226,267 HEV+NG 21,985 24,040 24,863 46,073 50,188 51,734 87,443 93,363 92,800 35,689 41,024 9,601 158,496 166,720 164,210 PHEV #REF! #REF! #REF! #REF! #REF! #REF! 100,377 94,849 89,253 68,391 65,673 64,579 #REF! #REF! #REF! Net CAPEX - Vehicle* Diesel 29,149 30,401 32,604 53,856 56,086 60,008 58,016 60,489 64,841 133,460 138,793 148,158 90,637 95,258 102,172 Natural Gas 31,550 32,528 34,329 72,020 73,016 75,167 82,766 82,900 83,836 142,523 145,398 151,065 160,924 161,750 151,703 Electric 108,688 105,272 82,790 98,527 104,551 92,622 62,572 64,947 69,142 116,268 120,752 128,652 90,936 94,428 100,583 HEV 48,149 50,032 49,152 76,756 79,348 79,821 82,916 88,544 89,123 137,367 79,348 151,735 156,800 164,751 170,767 HEV+NG 52,924 54,485 53,127 93,056 94,238 92,641 109,666 112,896 109,963 159,267 162,367 168,543 213,537 217,478 205,636 PHEV 42,749 45,163 45,030 71,796 74,896 76,088 146,016 135,285 122,246 155,360 157,481 162,595 102,577 111,068 115,252 CAPEX - Per Vehicle Infrastructure Diesel - - - - - - - - - - - - - - - Natural Gas - - - - - - - - - - - - - - - Electric 1,850 1,906 2,003 1,850 1,906 2,003 - - - - - - - - - HEV - - - - - - - - - - - - - - - HEV+NG - - - - - - - - - - - - - - - PHEV - - - - - - - - - - - - - - - TCO (dollars for year of purchase) Diesel 69,013 72,175 78,958 145,412 151,368 165,695 214,927 218,531 233,047 297,060 309,913 340,918 342,054 346,251 365,629 Natural Gas 61,315 65,870 70,954 141,294 150,778 160,500 198,403 210,620 218,646 273,849 293,899 316,641 347,189 360,982 356,775 Electric 123,017 120,116 99,394 158,901 164,102 154,113 66,504 69,011 73,735 118,477 123,028 131,211 97,382 101,153 108,301 HEV 85,216 87,284 88,436 157,107 155,491 159,913 220,077 219,155 220,325 189,097 155,491 153,144 388,451 389,306 397,034 HEV+NG 74,910 78,526 77,990 139,129 144,425 144,375 197,109 206,259 202,764 194,956 203,391 178,144 372,033 384,197 369,847 PHEV #REF! #REF! #REF! #REF! #REF! #REF! 246,393 230,134 211,499 223,751 223,154 227,175 #REF! #REF! #REF! Payback Period (Excluding Infrastructure) Diesel - - - - - - - - - - - - - - - Natural Gas 1 1 <1 9 11 7 5 7 5 2 2 1 5 6 4 Electric 23 19 10 8 9 5 <1 <1 <1 <1 <1 <1 <1 <1 <1 HEV 14 12 9 12 9 7 8 7 5 <1 <1 <1 8 7 6 HEV+NG 7 7 5 10 10 6 7 9 6 #VALUE! #VALUE! #VALUE! 6 6 4 PHEV >30 >30 >30 >30 >30 >30 15 10 5 2 2 1 #REF! #REF! #REF! Delivery Delivery Delivery Work Truck Intercity Truck Class 3 Class 4-6 Class 7-8 Class 6 Class 8 TCO Summary Notes: 1. CAPEX weighted based on proportion of total capacity used by an individual vehicle. For example if a truck used 10DGE /year of an available 100 DGE infrastructure that cost $100, then the per vehicle infrastructure CAPEX for that truck would be $10 2. The payback period listed in this table excludes infrastructure and battery replacements. Other payback periods including both of these costs can be found at the bottom of the individual Technology Worksheets 3. All costs are in present value $ for the year stated at the column head Class 3 Delivery Class 8 Intercity TCO: Lowest NG lowest, followed by diesel and NG+HEV Diesel, followed by NG HEV+NG & HEV Payback Period: Lowest NG (~ 1 year) followed by HEV+NG (5-7 years), and HEV (9-14 years) NG (4-6 yrs), followed by HEV+NG (4-6 yrs) and HEV (6-8 yrs) OPEX: Lowest EV HEV+NG CAPEX: Lowest Diesel Diesel = Best in vehicle class/duty cycle
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2013 7RD.12/272601.5 69 145 215 297 342 61 141 198 273 347 123 159 85 157 220 388 75 139 197 372 246 223 Diesel best: Class 8; NG best: Class 3 delivery; NG+HEV best: Class 4-6 & 7-8 delivery; PHEV best: Class 6 work truck TCO by Segment and Technology Source: Ricardo Fleet TCO Model TCO Model Output – Segment, Technology and Year Comparison Diesel Natural Gas Electric Vehicle 72 151 218 310 346 66 151 211 293 361 120 164 87 155 219 389 78 144 206 384 230 223 79 166 233 340 365 71 161 219 317 356 99 154 88 160 220 397 79 144 202 369 215 227 Class 3 Delivery Class 4-6 Delivery Class 7-8 Delivery Class 6 Work Truck Class 8 Intercity 2012 2015 2020 Key Takeaways Class 3: NG and diesel are lowest TCO. – NG +HEV is slightly higher than diesel vehicle – EV is consistently the highest driven by large CAPEX. Relatively small range for TCO except for Class 6 work truck – Driven by high initial vehicle price (relatively smaller percent change for the addition of new technologies) – Majority idle fuel usage – Longest period of ownership Class 8 Intercity has very low relative variation in TCO – Driven by short ownership period assumption – Mid range annual mileage assumption $1,000s$1,000s$1,000s 6 year TCO 12 year TCO 12 year TCO 15 year TCO 5 year TCO HEV NG-HEV PHEV Diesel NaturalGas NaturalGas NG-HEV PHEV NaturalGas NG-HEV NG-HEV PHEV NG NaturalGas NG-HEV NG-HEV PHEV Diesel Best-in-sector shown in green frame
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2013 8RD.12/272601.5 Class 3: For all but diesel, CAPEX exceeds OPEX. For highest cost vehicles, CAPEX is 1.5-9X higher than OPEX Class 3 Delivery TCO Net CAPEX and OPEX Contributors 29,149 31,550 108,688 48,149 52,924 30,400 32,528 119,860 50,030 54,485 32,604 34,328 108,152 49,152 53,127 1,850 1,906 2,003 39,134 27,581 12,480 31,067 21,985 55,220 30,533 12,938 37,252 24,040 61,011 33,420 14,601 39,294 24,863 68,283 59,131 123,018 79,216 74,909 85,620 63,061 134,704 87,282 78,525 93,615 67,748 124,756 88,446 77,990 Diesel Natural Gas Electric HEV NG+HEV Diesel Natural Gas Electric HEV NG+HEV Diesel Natural Gas Electric HEV NG+HEV Source: Ricardo Fleet TCO Model Example TCO Model Output – Class 3 Delivery Diesel Vehicle Net CAPEX Diesel OPEX CNG Vehicle Net CAPEX CNG OPEX EV Vehicle Net CAPEX EV OPEX EV Infrastructure CAPEX 2012 2015 2020 Key Takeaways Lowest OPEX by far is with EV, but highest CAPEX Lowest OPEX+CAPEX is CNG, followed by diesel Shorter ownership periods (6 years vs. 12-15 for other classes) lead to higher % contribution of Net CAPEX to overall TCO. Start-stop drive cycle favors electric vehicles in operating costs, but the high initial price significantly affects the TCO HEV Vehicle Net CAPEX HEV OPEX NG+HEV Vehicle Net CAPEX NG+HEV OPEX OPEX CAPEX
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2013 9RD.12/272601.5 $50,000 $55,000 $60,000 $65,000 $70,000 $75,000 $80,000 $85,000 $90,000 $95,000 $100,000 2012 2015 2020 CNG - Public Station CNG - Private Station CNG - In house 50 vehicles CNG - In house 100 vehicles CNG - In house 300 vehicles Nominal Diesel High Diesel Low Diesel Small fleets see little financial benefit from installing their own CNG infrastructure but may have few other options available Class 3 Delivery TCO: Multiple Pricing Cases TCO Comparison – Sensitivity to AssumptionsClass3DeliveryVehicleTCO Key Takeaways Use of private fueling stations leads to savings over public fueling stations Small and medium fleets (100 vehicle or less) see no financial benefit from installing on-site infrastructure Fleets >300 vehicles will justify infrastructure investment even with low diesel fuel costs 50 vehicle fleets can only justify infrastructure investment if diesel fuel cost is high The financial benefit of natural gas class 3 delivery vehicles diminishes in areas where there is a lack of public and private refueling infrastructure Assumptions: •Phoenix Urban Drive Cycle •No Natural Gas Incentives •No additional maintenance facility upgrades •Land costs not included in infrastructure costs Source: Ricardo Fleet TCO Model High Diesel $6.43/gal Nominal Diesel $4.67/gal Low Diesel $2.94/gal 50vehicles 100vehicles 300vehicles 50vehicles 100vehicles 300vehicles 50vehicles 100vehicles 300vehicles High Diesel $4.37/gal Nominal Diesel $3.90/gal Low Diesel $3.01/gal
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2013 10RD.12/272601.5 Class 8: OPEX >> CAPEX for diesel, OPEX is smaller % of total costs for LNG. LNG expected to outperform diesel in out years as diesel $ continues to rise, and technology cost matures 2 scenarios for LNG Class 8 Intercity are compared to a diesel baseline $90,637 $135,924 $160,924 $95,258 $137,749 $161,750 $102,172 $132,132 $151,703 $251,418 $146,136 $191,808 $250,992 $140,978 $183,785 $263,456 $133,728 $172,153 $342,055 $282,060 $352,732 $346,250 $278,727 $345,535 $365,628 $265,860 $323,856 Diesel NG Case1 NG Case2 Diesel NG Case1 NG Case2 Diesel NG Case1 NG Case2 Source: Ricardo Fleet TCO Model Example TCO Model Output – Sensitivity to Assumptions Diesel Vehicle Net CAPEX Diesel OPEX LNG Vehicle Net CAPEX LNG OPEX 2012 2015 2020 Case Descriptions / Key Takeaways Natural Gas Case 1: – In-house fuel cost – 120 DGE tank (~300 mile range) Natural Gas Case 2: – Public Pump fuel Price – 240 DGE tank (~600 mile range) 2020 Cost advantage of NG Case #1 due to lower pump price than in-house price, (~$35K) and lower cost of smaller fuel tank (~$25K) Downward cost trend of LNG due to increasing forecast of diesel price, and decreasing cost of LNG technology as technology matures and incremental cost penalty decreases OPEX CAPEX
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2013 11RD.12/272601.5 $200,000 $250,000 $300,000 $350,000 $400,000 $450,000 $500,000 2012 2015 2020 LNG - Public Station LNG - Private Station LNG - In house 50 vehicles LNG - In house 100 vehicles LNG - In house 300 vehicles Nominal Diesel High Diesel Low Diesel Sensitivity of infrastructure: high fuel consumption of Class 8 Intercity trucks makes on-site infrastructure more appealing Class 8 Intercity TCO: LNG fueling and infrastructure case evaluation Example TCO Model Output – Sensitivity to AssumptionsClass8IntercityVehicleTCO Key Takeaways High fuel consumption of Class 8 Intercity trucks makes on-site infrastructure more appealing than public or private fueling for fleets as small as 50 trucks Dependant on routes and distances travelled, this may only be true if a single hub in the shipping network has at least 50 vehicles: – This scenario only includes one filling station – Intercity trucks may not be able to return to that station at the end of the day Additional Assumptions: •No Natural Gas Incentives •No additional maintenance facility upgrades •Land costs not included in infrastructure costs •One LNG station per fleet •LNG transported 300 miles or less Source: Ricardo Fleet TCO Model High Diesel $6.43/gal Nominal Diesel $4.67/gal Low Diesel $2.94/gal High Diesel $4.37/gal Nominal Diesel $3.90/gal Low Diesel $3.01/gal 50vehicles 100vehicles 300vehicles 50vehicles 100vehicles 300vehicles 50vehicles 100vehicles 300vehicles
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2013 12RD.12/272601.5 Operating cost variables are effected by brake life, battery life, oil change intervals, filter replacements and oil cost Key observations: 1. Hybrid systems significantly reduce brake replacement frequency, significantly reducing maintenance costs for high mileage duty cycles. HEV brake maintenance savings more than offsets battery replacement costs for vehicles kept longer than the estimated 8 year battery life 2. NG: shorter oil change intervals, tank inspections, and more frequent filter replacements lead to slightly higher maintenance costs for natural gas vehicles. SI engines also require that natural gas engine oil be used. 3. NG HEV: maintenance costs offer significant reductions over conventional diesel vehicles Source: Peterbilt Hybrid System Maintenance Manual, NREL/TP-5400-53503, NREL Merit Review - Coca Cola, NREL/TP-540-44314, NREL/CR-540-42534 OPEX: Maintenance Notes: 1. This study does not take into account increased diagnostic time involved in introducing a new technology into your shop. In several NREL hybrid fleet studies, the troubleshooting of problems with HEV systems offset maintenance cost advantages. 2. Battery replacement PV is used for all model calculations. Annualized battery replacement is used only for illustrative comparisons between baseline and HEV maintenance. 3. New technology troubleshooting and low volume part scarcity potential with this technology are not considered in the model 4. Additional diagnostic costs associated with the repairs to new technologies are not included Class 3 Class 4-6 Class 7-8 Class 6 Class 8 Delivery Delivery Delivery Work Truck Intercity Truck HEV Maintenance and Overhead 693$ 1,234$ 854$ #VALUE! 2,598$ HEV Brake Maintenance 161$ 250$ 282$ -$ 589$ HEV Other Maintenance and Overhead 533$ 743$ 494$ #VALUE! 2,010$ HEV Battery Replacement (annualized) -$ 241$ 79$ #VALUE! -$ HEV Battery Replacement (PV) -$ 2,896$ 945$ #VALUE! -$ Diesel Maintenance and Overhead 1,255$ 1,877$ 1,949$ 3,425$ 4,360$ Diesel Brake Maintenance 804$ 1,248$ 1,472$ 2,944$ 2,944$ Diesel Other Maintenance and Overhead 451$ 629$ 477$ 481$ 1,416$ Class 3 Class 4-6 Class 7-8 Class 6 Class 8 Delivery Delivery Delivery Work Truck Intercity Truck Natural Gas Maintenance and Overhead 1,748$ 2,155$ 2,606$ 3,653$ 5,831$ Diesel Maintenance and Overhead 1,500$ 1,877$ 2,181$ 3,425$ 4,360$ Class 3 Class 4-6 Class 7-8 Class 6 Class 8 Delivery Delivery Delivery Work Truck Intercity Truck NG-HEV Maintenance and Overhead 779$ 1,318$ 1,423$ -$ 2,532$ Baseline Diesel Maintenance and Overhead 1,255$ 1,877$ 1,949$ 3,425$ 4,360$
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2013 13RD.12/272601.5 Conclusions Commercial vehicles were modeled with 6 powertrain technology configurations, including diesel as the baseline powertrain, and 22 combinations of powertrain & vehicle/duty cycle TCO: – TCO can be reduced by 14% or increase by as much as 80% depending on technology, duty cycle, infrastructure and fuel costs – Operating cost variation is effected by brake life, battery life, oil change intervals, filter replacements and oil cost Payback period: – Payback period for introducing new technology ranges from 1 to 23 years • 1 year: Class 3 delivery NG, and Class 6 work truck NG and PHEV • 23 years: Class 3 delivery EV, driven by CAPEX: battery pack, motor and power electronics, charging infrastructure and low volumes associated with new technology – Payback period is sensitive to infrastructure requirements paced by fleet size, the rate of diesel fuel cost increase and desired vehicle range (battery or tank size) Technology choice for lowest TCO: – Diesel best: Class 8 – NG best: Class 3 delivery Next steps: expand to more technologies, and more applications such as off highway, agriculture, mining, marine, power generation… – NG+HEV best: Class 4-6 delivery & 7-8 delivery – PHEV best: Class 6 work truck
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2013 Total Cost of Ownership: Economics of Emerging Fleet Technologies Thank you! Links: American Gas Association Natural Gas Fleet Savings Calculator http://www.aga.org/our-issues/natural-gas-vehicles/Pages/Natural-Gas-Fleet-Savings-Calculator.aspx Or Google: Ricardo Fleet Savings Calculator Ricardo Strategic Consulting•Ricardo Inc. Detroit Technology Campus, 40000 Ricardo Drive Van Buren Twp., Michigan 48111 USA Christopher Yee Manager Telephone: +1 734.306.5055 Facsimile: +1 734.397.6677 louis.bailoni@ricardo.com Ricardo Strategic Consulting•Ricardo Inc. Detroit Technology Campus, 40000 Ricardo Drive Van Buren Twp., Michigan 48111 USA Mark S. Kuhn, P.E. Principal Mark.kuhn@ricardo.com Mobile: +1 248 819 5744 Recption: +1 734 397 6666 Facsimile: +1 734 397 6677 www.ricardo.com
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