Comprehensive Well-to-Wheel Life Cycle Assessment of Battery Electric Heavy-Duty Trucks Using Real-World Data: A Case Study in Southern California

This study presents a well-to-wheel life-cycle assessment (WTW-LCA) comparing battery-electric heavy-duty trucks (BEVs) with conventional diesel trucks, utilizing real-world fleet data from Southern California’s Volvo LIGHTS project. Class 7 and Class 8 vehicles were analyzed under ISO 14040/14044 standards, combining measured diesel emissions from portable emissions measurement systems (PEMSs) with BEV energy use derived from telematics and charging records. Upstream (“well-to-tank”) emissions were estimated using USLCI datasets and the 2020 Southern California Edison (SCE) power mix, with an additional scenario for BEVs powered by on-site solar energy. The analysis combines measured real-world energy consumption data from deployed battery electric trucks with on-road emission measurements from conventional diesel trucks collected by the UCR team. Environmental impacts were characterized using TRACI 2.1 across climate, air quality, toxicity, and fossil fuel depletion impact categories. The results show that BEVs reduce total WTW CO<sub data-eusoft-scrollable-element="1">2</sub>-equivalent emissions by approximately 75% compared to diesel. At the same time, criteria pollutants (NO<sub data-eusoft-scrollable-element="1">x</sub>, VOCs, SO<sub data-eusoft-scrollable-element="1">x</sub>, PM<sub data-eusoft-scrollable-element="1">2.5</sub>) decline sharply, reflecting the shift in impacts from vehicle exhaust to upstream electricity generation. Comparative analyses indicate BEV impacts range between 8% and 26% of diesel levels across most environmental indicators, with near-zero ozone-depletion effects. The main residual hotspot appears in the human-health cancer category (~35–38%), linked to upstream energy and materials, highlighting the continued need for grid decarbonization. The analysis focuses on operational WTW impacts, excluding vehicle manufacturing, battery production, and end-of-life phases. This use-phase emphasis provides a conservative yet practical basis for short-term fleet transition strategies. By integrating empirical performance data with life-cycle modeling, the study offers actionable insights to guide electrification policies and optimize upstream interventions for sustainable freight transport. These findings provide a quantitative decision-support basis for fleet operators and regulators planning near-term heavy-duty truck electrification in regions with similar grid mixes, and can serve as an empirical building block for future cradle-to-grave and dynamic LCA studies that extend beyond the operational well-to-wheels scope adopted here.