Zero-Emission Refuelling Truck in Daily Airport Operations

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Client

Confidential UK Airport

Vehicle

Electra Zero-Emission Refueling Truck

Application

Aircraft Ground Refuelling

Electra Commercials supplied a zero-emission refuelling truck to a major UK airport, aiming to decarbonize airside operations without compromising performance or reliability.

The vehicle operates on a 140 kWh battery platform, delivering up to 900 litres per minute flow rate and 20,000-litre fuel tank capacity, while maintaining operational readiness across demanding duty cycles.

This case study summarizes key insights from one full year of real-time performance data, diagnostics, and energy efficiency monitoring.

Key Results

9 Aircraft Fuelled in One Day

34,000 litres delivered using just 21% of battery SoC Equivalent to only 7.9 kWh used (0.23 Wh/litre)

Low Daily Energy Use

Average daily consumption: 16 kWh
Estimated cost: £4.20 per day
CO₂ emissions: 3 kg/day

Efficient Weekly Operations

Charges once per week
Weekly charging cost: £21
End-of-week SoC typically ~40%

Minimal Battery Degradation

SoH decline of just 2.4% over 1.5 years indicates excellent long-term viability

Operational Analysis.

One-Day Utilization Snapshot

A focused data analysis was conducted on a representative operational day. The truck fuelled nine aircraft and delivered 34,000 litres of fuel.

Despite the high output, only 21% of battery charge was consumed, demonstrating exceptional energy efficiency.

Flow rate: Up to 900 LPM
SoC used for fuelling only: 7.9 kWh
Total energy consumption (daily): 16 kWh

Annual Utilisation Overview

Over the year:

Distance travelled: 1,576 km
Total energy consumed: 4,984 kWh
Charging cycles: Weekly
Typical weekday use: 5 km of movement and moderate fuelling demand

Battery Health and Diagnostics.

Electra’s real-time monitoring platform provides advanced diagnostics on battery performance and usage patterns.

98.4%

Battery health (SoH) after 1 year

97.6%

Battery health (SoH) after 1.5 years

Monitored through CATL algorithms and internal fault detection systems
No critical fault trends observed over the monitored period

Conclusions

This case study concludes the operational and economic viability of Electra’s zero-emission refuelling trucks in high-demand environments such as airports:

Exceptional Efficiency: Minimal energy per litre pumped
Low Running Costs: Just £4.20 per day average
Low Emissions: 3 kg CO₂ equivalent per day
High Uptime: Reliable weekly charging and minimal SoH drop
Robust Diagnostics: Real-time fault detection and performance tracking

Electra’s commitment to data transparency and operational reliability is helping airports meet sustainability targets while ensuring uninterrupted airside performance.