DOT HS 812 177 June 2015 Commercial Medium- And Heavy-Duty Truck Fuel Efficiency Technology Cost Study This publication is distributed by the U.S. Department of Transportation, National Highway Traffic Safety Administration, in the interest of information exchange. The opinions, findings and conclusions expressed in this publication are those of the author(s) and not necessarily those of the Department of Transportation or the National Highway Traffic Safety Administration. The United States Government assumes no liability for its content or use thereof. If trade or manufacturer’s names or products are mentioned, it is because they are considered essential to the object of the publication and should not be construed as an endorsement. The United States Government does not endorse products or manufacturers. Suggested APA Format Citation: Schubert, R., Chan, M., and Law, K. (2015, June). Commercial medium- and heavy-duty truck fuel efficiency technology cost study. (Report No. DOT HS 812 177). Washington, DC: National Highway Traffic Safety Administration. TECHNICAL REPORT DOCUMENTATION PAGE 1. Report No. 2. Government Accession No. 3. Recipient's Catalog No. DOT HS 812 177 4. Title and Subtitle 5. Report Date Commercial Medium- and Heavy-Duty Truck Fuel Efficiency Technology June 2015 Cost Study 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. Ray Schubert, Michael Chan, and Karen Law 100-TAG-T30999 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) Prepared for: Prepared by: Thomas E. Reinhart Michael Chan 11. Contract or Grant No. Southwest Research Institute Tetra Tech, Inc. GS-23F-0006M/DTNH22- 6220 Culebra Road 3475 E. Foothill Blvd. 12-F-00428 San Antonio, TX 78228-0510 Pasadena, CA 91107 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered National Highway Traffic Safety Administration Technical Report 1200 New Jersey Avenue SE. 14. Sponsoring Agency Code Washington, DC 20590 NHTSA/NVS-132 15. Supplementary Notes Contracting Officer’s Technical Representatives (CORs): Technical Advisor: Dr. John Whitefoot and James MacIsaac Coralie Cooper Volpe National Transportation Systems Center National Highway Traffic Safety Administration Energy Analysis and Sustainability Division Fuel Economy Division, NVS-132 55 Broadway 1200 New Jersey Avenue SE. Cambridge, MA 02142 Washington, DC 20590 16. Abstract This report accompanies the work performed by Southwest Research Institute (SwRI) in collaboration with the National Highway Traffic Safety Administration on fuel efficiency and emissions reduction technologies. Technologies are evaluated for medium- and heavy-duty vehicles for model years 2019 and beyond. Based on the list of technologies and configurations identified by SwRI, this report examines the costs of implementation in constant 2011 U.S. dollars in the areas of incremental retail prices and life cycle cost elements. Incremental retail prices are evaluated relative to the prices of the specific baseline technologies that would otherwise be used in the vehicles if the fuel efficiency and emissions reduction technologies were not implemented. These prices include the technology components as well as their installation and incorporation in the vehicle. These prices account for all costs associated with the manufacturers and suppliers’ production and sale of the technologies to the retail purchaser. The life cycle cost element examines the costs of using the technologies during the vehicles’ lifetimes and are intended to inform separate, full-scale, life-cycle analysis. This report provides the overall details of the costing methodology and findings of the study. Note: This report was subjected to external peer review per OMB guidelines for a Highly Influential Scientific Assessment (HISA). Material from the peer review process are publicly available in accompanying documents. 17. Key Words 18. Distribution Statement Fuel Consumption, GHG Emissions, Medium Duty Truck, Document is available to the public from Heavy Duty Truck, Engine Technology Cost, Vehicle the National Technical Information Technology Cost Service www.ntis.gov 19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. No. of Pages 22. Price Unclassified Unclassified 279 Form DOT F 1700.7 (8-72) Reproduction of completed page authorized i Acknowledgments The authors gratefully acknowledge the guidance and assistance of Thomas Reinhart of Southwest Research Institute; Brian Dahlin, James MacIsaac, and John Whitefoot of the National Highway Traffic Safety Administration; and Coralie Cooper and Ryan Keefe of Volpe National Transportation Systems Center. ii Table of Contents Executive Summary ................................................................................................................. xvii Abbreviations ........................................................................................................................ xxvii 1 Introduction ................................................................................................................... 1 2 Fuel Efficiency and Emissions Reduction Technologies ................................................... 2 3 Incremental Retail Prices ................................................................................................ 9 3.1 Advanced Bottoming Cycle .................................................................................. 22 3.2 Coolant/Oil Pump ................................................................................................ 24 3.3 Variable Valve Actuation (priced per vehicle) ...................................................... 29 3.4 Cylinder Deactivation........................................................................................... 35 3.5 Stoichiometric GDI ............................................................................................... 37 3.6 Lean Burn GDI with SCR ....................................................................................... 39 3.7 Stoichiometric GDI+EGR ...................................................................................... 41 3.8 Turbocharging and Downsizing ............................................................................ 42 3.9 Engine Downspeeding ......................................................................................... 44 3.10 Low-Friction Engine Oil (priced per vehicle) ..................................................... 45 3.11 Engine Friction Reduction ................................................................................ 51 3.12 Stop/Start ........................................................................................................ 56 3.13 Reduced Aftertreatment Backpressure ............................................................ 60 3.14 Air Handling Improvements ............................................................................. 61 3.15 Mechanical Turbocompound ........................................................................... 62 3.16 Electric Turbocompound .................................................................................. 63 3.17 Hybrid Electric Vehicles .................................................................................... 65 3.18 Diesel APU (with DPF) ...................................................................................... 71 3.19 Battery APU ..................................................................................................... 72 3.20 Fuel-Fired Heater ............................................................................................. 73 3.21 Air Conditioner System Improvements............................................................. 74 3.22 Cab Insulation to Reduce A/C ........................................................................... 77 3.23 Air Compressor Improvements ........................................................................ 80 iii 3.24 Shore Power ..................................................................................................... 81 3.25 Aero Bin III ....................................................................................................... 82 3.26 Aero Bin IV and V ............................................................................................. 84 3.27 Include Trailer Cd and Crr in Rule ....................................................................... 87 3.28 Aero on Regional Haul ...................................................................................... 87 3.29 Class 2b&3 Improved Aerodynamics ................................................................ 88 3.30 Improved Transmissions .................................................................................. 89 3.31 Automated Manual Transmission .................................................................... 94 3.32 Dual Clutch Automatic ..................................................................................... 96 3.33 Low Rolling Resistance Tires (priced per tire) ..................................................100 3.34 Single Wide Tires (priced per tire/wheel replacing 2 standard width tires/wheels) ................................................................................................................103 3.35 Automatic Tire Inflation System ......................................................................104 3.36 Weight Reduction ...........................................................................................106 3.37 6x2