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Pioneering KCI Amps Up Their Shuttle Bus Fleet

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Kansas City International Airport is no stranger to cleaner fuels.  It began deploying compressed natural gas (CNG) buses back in 1997, providing natural gas on site with its own high-speed fueling station.  This made the Aviation Department something of a pioneer in alt-fuel adoption.  The next step, though, was a big jump in fuel efficiency, and in October of 2017, KCI became the first US airport to deploy all-electric shuttle buses.  It’s currently running 7 BYD K7 battery-electric shuttles along with older CNG units. 

There’s no getting around the fact that up-front costs for electric vehicles are going to be higher than for equivalent conventional buses.  In fact, when the airport rolled out data on the comparative costs of different fuels, the contrast was stark.  A brand-new diesel shuttle buses cost about $385,000; for CNG, add an additional 14% for a sticker price of $440,000.  All-electric models come in at a fairly eye-popping $540,000, more than 40% more expensive than the price for a baseline diesel.   

But as anybody who’s bought a car knows, the sticker price isn’t the only price.  The sticker price, in fact, is only the beginning of years of recurring costs.  Kenny Williams is the Fleet Asset Manager for the Aviation Department and one of the main proponents of the EV deployment back in 2016-17 as the project began to take shape.  He broke it down as follows: 

Costs Per Mile (Including fuel and maintenance) 
  • Diesel – variable/volatile fuel prices; approximate costs $1.50/mile 
  • CNG – more stable fuel prices; approximate costs $1.00/mile, $0.45-.50 w. alt-fuel tax credit 
  • Electric – fixed fuel prices; approximate costs $0.50/mile 

Maintenance costs add up quickly for the shuttle bus duty cycle.  Oil changes for CNG units are about $170 and have to happen every other month.  Annual tune-ups add an additional $3,800 to CNG bus operating costs.  So, even with fuel at an economical $0.50/gallon thanks to the clean fuel tax credit, CNG bus maintenance per year comes in between $4,800 and $5,000 per unit.  It’s not like EV buses float on air.  Like CNG units, they need new tires, and fluid changes every 18 months add annual costs of about $165 per year.  But no internal combustion engine means no tune-ups, avoiding the lion’s share of regular maintenance overhead. 

And yet, even with maintenance savings of around $50,000 per bus over ten years, there’s still a big price gap between diesel, CNG and electric buses.  That’s where federal clean-fuel funding comes in.  Thanks to support from the US Department of Energy, KCI was eligible for reimbursements of $72,000 per bus, dropping their costs to just $2,000 more than comparable CNG shuttles.   

The same grant, “Accelerating Alternative Fuel Adoption in Mid-America” provided funding for charging infrastructure, covering about $100,000 of $225,000 in construction and equipment costs for the new systems.  KCI’s electric bus charging lot has eight pedestals installed, with space for an additional four slots if more EV units are purchased.   Charging time is about three hours, and this “fueling” process hasn’t had any negative impact on operations.   

Kenny Williams talks EV bus duty cycles at the airport’s charging lot.

What has the driver response been like?  Per Kenny Williams, “For most drivers, once they drive them, they really like them.”  The only minor hitch has been how drivers operate the bus HVAC systems – since they are battery-driven, power loss from cranking up AC or heating at full throttle can take a bite out of driving range when a gentler touch would work better. And KCI is planning on investing in additional EV units.  The economic toll of the pandemic has postponed acquisition of a few of the 12 units originally planned.  However, the Aviation Department is planning on ordering three more units in addition to the seven already in service.  These new buses will be slightly different.  They’ll have inductive charging systems, which will let them power up without cords or plugs, as they pick up passengers at the new terminal starting in early 2023.   

This material is based upon work supported by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) Vehicle Technologies Program under Award Number DE-EE0008262 . 

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Photo by: Anissa Parra-Grooms, Metropolitan Energy Center

All-Electric Terminal Trucks Make Great Business Sense

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Metropolitan Energy Center (MEC) announces the first placements of all-electric zero-emission Class-8 yard trucks into service under a new grant project. The project, “Electrifying Terminal Trucks in Unincentivized Markets,” is the result of partnerships from Kansas City to Chicago, whose goal is to electrify terminal trucks in our regional market. The first placements of four planned have taken place at funding recipient Firefly Transportation Services. Based in Glenview, IL, Firefly provides zero-emission transportation options to freight yard, port and cargo sites, along with training and site preparation for all-electric operations.

The vehicles funded under this grant are manufactured by Orange EV. Based in Riverside, MO, Orange EV designs and manufacturers all-electric yard trucks right here in the heartland. They are also the first American company to commercially build, deploy and service 100% electric Class-8 electric vehicles. Before this year, Orange EV had yet to deploy one of their vehicles in the Kansas City area. Jason Dake, Vice President of Legal and Regulatory Affairs at Orange EV stated, “Not selling one of our trucks in our own backyard was a thorn in our side for a while,” he continued, “Seeing additional trucks deployed in the metro area through the project is a great feeling and most importantly, they are helping our community and improving the air quality for Kansas Citians.”

Additional funding recipients with all-electric truck placements planned in the near future are the Johnson County Wastewater Department in Leawood, KS and Hirschbach Motor Lines, a private long-haul carrier with emphasis on refrigerated and other specialized services. Hirschbach will deploy their truck at a client site in Wyandotte County, KS. Both Evergy and the Unified Government of Wyandotte County, Kansas City, Kansas Board of Public Utilities will provide technical assistance, as needed, on electrical service and electric rate guidance.

Orange EV will also take possession of a demonstration truck to provide potential customers across the U.S. up to a 2- to 4-month trial period. During the period, they can use the tractor free of charge, viscerally demonstrating air quality, noise-reduction and cost-savings benefits in their unique work environments.

Yard trucks (also known as hostlers, terminal tractors, goats or mules) are designed to pull cargo containers and semi trailers in freight or intermodal yards, or at large manufacturing sites. The workload for these trucks is intense, pulling heavy loads almost continuously. The power required means that most yard trucks are diesel, which results in a great deal of diesel exhaust, one of the worst pollutants and a major source of poor air quality. Diesel exhaust is not only a health risk for workers on site, but it also threatens communities surrounding industrial zones, typically low-income neighborhoods. Even worse, low speed, high-power operations emit much more soot and other particulates than diesel operations at highway speeds. Systematically replacing diesel yard trucks with electric models could substantially boost air quality in and around America’s busiest freight hubs. At the same time, the cost savings both from eliminating diesel fuel and from operating a much more efficient electric powertrain is an attractive advantage.

However, the project is not only about improving air quality and saving money. Another key goal is to gather data on electric truck operations to validate broader deployments of battery-powered yard trucks. Telematics and data, supported by fleet interviews and operational evaluation, will be analyzed by another project partner and nearby neighbor, Missouri University of Science and Technology. Ultimately, MEC will create a deployment guide based on the real-world experiences of our project partners in Chicago and Kansas City so fleet operators across the country can make the move to cleaner, more efficient freight handling.

To learn more about this project or to request the demo truck for your work site, please contact Emily Wolfe.

This material is based upon work supported by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) under the Award Number DE-EE0008887.

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Electric Cars – Parity and Prospects

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To the casual observer, battery-electric vehicles (BEVs) appear nestled comfortably on the upslope of a growth curve that would turn other industries green – with envy, in this case.  From a global grand total of about 20,000 EVs of all makes on the road in 2010, by 2019, the total number of plug-in hybrid (PHEV) and full electric autos on the road worldwide rose to 7.2 million.  That’s an almost a 360-fold increase in less than a decade.

The biggest surprise to date has been the number of surprises to date.  Who imagined that an automotive startup – the first such large-scale attempt since Kaiser-Frazier back in 1947 – would flat-out pound legacy OEMs in the US in any market segment?  In 2019, Tesla’s three all-electric models outsold GM’s EV/PHEV Bolt and Volt combined by nearly nine to one.  Also in 2019, the California upstart commanded more than 78% of US BEV market share.

Who imagined that battery costs would continue to collapse at the rate we’ve seen through 2019?  In 2010, battery costs per kwh averaged about $1,100 – in 2019, they hit a new low of $156.  Who imagined that price parity between EVs and conventional ICE models could arrive in some market segments by as soon as 2022, 2023, or 2025?  What year, of course, depends on whether the crystal ball you’re consulting belongs to Deloitte, Roskill or Carnegie Mellon University.

It’s this last bit – predicting the crossover– that we want to take a look at today.  Not surprisingly, it’s complicated.  Total cost of ownership for an EV can be substantially lower than for an ICE car.  With simple drive trains, EVs have fewer points of failure, and electricity is cheaper than gasoline in most industrialized nations.  Tax incentives and rebates can substantially sweeten the pot.  But in the words of a recent Automotive News article, mass EV adoption is “inevitable, yet elusive.”

Multiple factors are in play.  Infrastructure buildout is slower than it could be.  Manufacturers may increase their margins once EVs hit a tipping point, given the substantial sunk costs they’ve already incurred.  Moving the needle on consumer acceptance is still difficult.  Though we’re expecting the arrival of multiple EV models by multiple OEMs by 2023, 14 different brands didn’t offer a single EV option as recently as the end of 2018.  And there’s still a rough $6,000 – $9,000 gap between EV models and their ICE counterparts in non-luxury categories.  In the end, it may be mandates that do the heavy lifting.  For all of the reasons above, and given Americans’ aversion to mandates, IHS Markit projects 40% of EU cars will be hybrid or pure EV by 2031, compared with 20% of the American passenger fleet.

Above and beyond the usual suspects, there’s one you might not have suspected – reliability.  At least in the US, drivers are holding onto their cars longer than ever, thanks in part to better quality.  By this July, the average age of an American car was a record 11.9 years, and per IHS, one in four cars on the road in the United States are more than 16 years old.  This is something of a tribute to improved automotive quality:  as noted in the article linked above, “Back in the ’90s, one-quarter of cars parked at the grocery store were not Ford Mavericks and Chevy Vegas. Nowadays, that beige 2002 Corolla is still ubiquitous.”

With COVID driving economic worries for consumers, auto purchases may be viewed as more discretionary than ever, particularly when it comes to buying a new car.   At the same time, until the pandemic is under control, road trips (vs. flying) and commuting by car (not public transit) may keep long-term auto demand simmering, even as our wheels continue to gray.  How all of the preceding will drive EV acceptance in the next few years is hard to forecast, but we’ll be watching closely.

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New Home For MEC – We’re Moving!

After 35 years in the heart of Kansas City, Missouri, Metropolitan Energy Center and Kansas City Clean Cities are moving to . . . the heart of Kansas City, Missouri.  We’re upping stakes next week and heading just a bit west and north of our old digs at 38th and Paseo.

Our new office will be located just west of the Bank of America at the southwest corner of 31st and Main.  Our official address will be 31 West 31st Street, Kansas City, MO  64108.  Beyond that, our contact information will remain unchanged.  And just in case you’ve had issues making contact with MEC staff in the past few days – well, now you know why.

MEC Communications Coordinator Beth Pauley hard at work in our new offices.

At the moment, the office is a maelstrom of boxes and cardboard and packing tape and long-forgotten teapots and scuba diving gear (no, seriously – it’s amazing what you find when you’re in the middle of moving).  And while we’ll miss our old home, we’re looking forward to a cool new location.  Fittingly enough, it’s in a building that was restored and rebuilt – just our style.

When you drop by, feel free to park in the lot immediately east of the office – just don’t park among the U-Haul trucks on the west wall of the lot.  There are spaces right in front of 31 West 31st, but it can get a bit tight backing out when leaving during rush hour.

We look forward to welcoming you to our new space, and to more great years ahead!

 

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