A two-layer programming for highway heavy-duty truck battery swapping stations

Xu Hao, Minjie Cao, Liguo Li, Sai Zhang, Xianming Meng, Bo Liu and Hewu Wang

Energy, 2025, vol. 321, issue C

Abstract: Battery-swapping heavy-duty trucks (HDTs) have emerged as a significant solution for freight electrification. However, as battery-swapping HDTs evolve from short-haul to long-haul operations, there remains a lack of comprehensive research addressing the joint optimization of station siting and in-station resource allocation along major highway corridors. This study develops a bi-level planning model for the techno-economic analysis of battery-swapping stations aimed at minimizing construction costs while maximizing service demand to achieve an optimal balance between investment efficiency and service quality. Using a highway case study in China, we identify vehicle arrival frequency and battery capacity as critical factors influencing per-unit transport costs. In single-station scenarios, smaller-capacity batteries (e.g., 282 kWh) result in higher comprehensive ton-kilometer costs than larger-capacity batteries at low arrival frequencies. However, as vehicle arrival frequency increases above 2 vehicles per hour, smaller-capacity batteries achieve cost reductions that surpass those of larger-capacity batteries. At the corridor level, both arrival frequency and battery capacity significantly impact station layout, showing trends consistent with single-station analysis. In this highway case, the 421 kWh battery configuration better meets demand. This study provides practical insights for cost-effective and scalable deployment of battery-swapping infrastructure for HDTs on major highways.

Keywords: Battery-swapping heavy-duty truck; Highway siting; Battery-swapping station; Two-layer programming; Economic analysis (search for similar items in EconPapers)
Date: 2025
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Persistent link: https://EconPapers.repec.org/RePEc:eee:energy:v:321:y:2025:i:c:s036054422501103x

DOI: 10.1016/j.energy.2025.135461

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