Electric truck charging infrastructure

Key facts at a glance

Europe’s public charging stations have more than doubled to 700,000 by Q1 2024, but an estimated 3.4 million will be required by 2030.
Heavy-duty vehicles (HDVs) need extensive infrastructure, including up to 50,000 high-power chargers (over 500 kW) and 40,000 lower-power chargers by 2030.
Germany, the Netherlands, and France are at the forefront of developing charging networks, with significant infrastructure already in place.
Milence is investing 500 million euros to establish 1,700 public electric vehicle (EV) charging stations by 2027, incorporating megawatt charging capabilities for rapid recharging of long-haul trucks.

However, the distribution of these charging points is uneven. Three countries – Netherlands, France, and Germany – house about 61 percent of all chargers, highlighting a significant imbalance across the continent.⁴ Additionally, only 13.5 percent of all charging points currently offer ev fast charging capabilities, underlining the necessity for an increase in high-capacity chargers to accommodate the growing adoption of battery electric vehicles (BEVs).⁵

10,000 to 15,000 higher-power public and destination charging points by 2025.
40,000 to 50,000 charging points by 2030, with the majority being high-power chargers of more than 500 kW.
40,000 lower-power (100 kW) public overnight chargers at truck parking areas along motorways by 2030.

Currently, there are over 6,000 charging points across Europe with a capacity suitable for trucks (above 350 kW), which is a significant increase from less than 3,600 such points a year ago.⁷Despite this progress, the infrastructure still needs to expand considerably to meet future demands.

The electrification of heavy-duty vehicles requires diverse charging solutions to accommodate varying power needs and operational demands. Electric truck charging stations range from 300 kW stations for rapid energy transfer to more advanced Megawatt Charging Systems (MCS) capable of delivering up to 3.5 MW. Each type of station is equipped with specific technologies and components to ensure efficient, safe, and reliable charging.

300 kW charging stations

300 kW charging stations for heavy-duty vehicles are designed to provide efficient and reliable high-power charging capabilities. These stations are equipped with several critical components and advanced technologies to ensure rapid energy transfer and manage the substantial power requirements of electric trucks.

High-power DC chargers, capable of delivering up to 300 kW, are essential for fast charging large battery packs in heavy-duty vehicles.
Advanced cooling systems manage the significant heat generated during these high-power charging sessions. These systems can include liquid cooling or advanced air cooling technologies.
Connectors and cables, specifically CCS connectors, are standardised for heavy-duty vehicle charging and are built to withstand frequent use and harsh conditions.
Power electronics such as inverters and converters are crucial as they convert AC power from the grid to DC power for the vehicle’s battery, ensuring high energy efficiency and stable power delivery.

Safety and protection mechanisms

Safety is paramount in these charging stations. Overcurrent protection mechanisms are in place to prevent damage from excessive current flow. Insulation monitoring systems are used to prevent electrical leaks, ensuring safe operations. Furthermore, emergency shutdown features provide both manual and automatic responses to faults or emergencies, enhancing the overall safety of the charging process.

Integration with energy management systems

These charging stations are integrated with energy management systems to optimise efficiency. Grid connectivity ensures efficient power use and load balancing. Additionally, energy storage systems are often incorporated to manage demand and supply effectively, enhancing the reliability of the charging infrastructure.

Charging time

In the realm of fast charging, it's clear that charging capacities above 300 kW are typically needed to recharge a battery from 20 to 80 percent within one to two hours.⁸

For the Daimler eActros 300, with a battery capacity of 336 kWh (3 packs of 112 kWh each), the charging time from 20 to 80 percent using a CCS charger is approximately 1 hour and 15 minutes.⁹
For the Volvo FH Electric, which has a battery capacity range of 360-540 kWh (4-6 batteries), charging time using a DC charger (250 kW) is approximately 2.5 hours.¹⁰

Current Status

Europe has been expanding its network of high-power charging stations, including those with 300 kW capacity. In early 2023, Europe launched its first truck charging corridor along a 600 kilometres stretch of the Rhine-Alpine corridor, one of the busiest road freight routes in Europe, featuring six public charging locations equipped with 300 kW charging points.¹¹The current status includes approximately 160 truck-specific charging points deployed across Europe.¹²

Combined Charging Systems (CCS), up to 400 kW

The primary difference between 300 and 400 kW charging stations lies in their power output and the corresponding equipment requirements. Both types utilise high-power DC chargers, advanced cooling systems, CCS connectors, robust power electronics, user interfaces, and safety mechanisms. However, 400 kW chargers require more robust or additional cooling systems to handle the extra heat generated by the higher power output.

They also need potentially larger or more efficient electrical components, such as inverters and converters, to manage the increased power flow. These enhancements ensure that 400 kW chargers can deliver higher power more efficiently and safely compared to their 300 kW counterparts.

Charging time

CCS chargers, which can go up to 400 kW, take a few hours to fully charge a truck from 0 to 100 percent.¹³

The Daimler eActros 300 can also be charged at a 400 kW charging station, with the charging time slightly reduced compared to 300 kW stations due to the higher power output, although exact times for 400 kW were not specified.⁹
The Volvo FH Electric can also utilise 400 kW charging stations. Compared to 300 kW charging stations, the charging time for the Volvo FH Electric is shorter due to the increased power output, although specific times can vary based on the battery configuration and state of charge.¹⁰

Current status

While exact numbers can fluctuate with ongoing installations and developments, estimates suggest that there are several hundred 400 kW charging stations either operational or planned across Europe. This includes contributions from major networks and independent charging hubs aimed at supporting the increasing adoption of electric heavy-duty vehicles.

Role of Milence

Milence is expanding its charging network to support the electrification of heavy-duty vehicles across Europe. Currently, it operates several 400 kW charging hubs in Belgium, Netherlands, and France. The company plans to open six further charging hubs in Sweden, Germany, and France in 2024.

Megawatt Charging Standard (MCS)

Despite this progress, more infrastructure is required to meet the projected demand by 2030. According to ACEA, Europe needs between 40,000 to 50,000 high-power charging points by 2030, with the majority being more than 500 kW.¹⁴

Megawatt Charging Systems (MCS) require significantly advanced technical equipment compared to 300 kW and 400 kW stations. They need ultra-high-power DC chargers capable of delivering up to 3.5 MW, enhanced cooling systems to manage substantial heat, and reinforced connectors and cables to handle higher currents. Additionally, they require advanced power electronics for stable power delivery and high-capacity grid connections, including dedicated substations and energy storage systems, to manage the massive power demand and ensure grid stability.

Charging time

MCS chargers can fully recharge a truck from 0 to 100 percent significantly faster than CCS chargers. They allow trucks to utilise only their mandatory rest periods for charging, ensuring that operational schedules remain unaffected. While CCS is adequate for longer duration charging, such as overnight, MCS enables long-haul traffic with a charging time of approximately 45 minutes.¹⁵

The charging time for the Daimler eActros 300 would be significantly less, enabling almost full charges during mandatory rest breaks for drivers.⁹
Similarly, the Volvo FH Electric would benefit from much faster charging times, allowing efficient long-haul operations with minimal downtime.¹⁰

Current status

Megawatt Charging Systems (MCS) in Europe are advancing with several key projects and investments. Projekt “Hochleistungsladen im Lkw-Fernverkehr” (HoLa, engl.: High Performance Charging for Long-Haul Trucking”) is implementing and testing eight MCS points in Germany, aiming for a network of at least 1,000 points by 2030.¹⁶ Companies like ABB, Autel Energy, BP Pulse, Kempower, Kverneland Energi, and Milence are investing heavily in MCS technology across Europe, with projects in Germany, the UK, Norway, and France.¹⁷These developments are crucial for supporting the electrification of heavy-duty transport.

Role of Milence

Building on these developments, Milence, a joint venture formed by Daimler Trucks, Traton Group, and Volvo Group, plans to invest 500 million euros to set up 1,700 public charging stations by 2027. These stations, which will be spread across Germany, the Netherlands, France, Belgium, Spain, Sweden, and Norway, will include megawatt charging capabilities.¹²This electric truck charging infrastructure will support charging speeds of up to 1,000 kW, allowing long-haul trucks to be fully charged in just 30 to 45 minutes.¹⁸

Which countries have a well-developed electric truck charging infrastructure?

The AFIR (Alternative Fuels Infrastructure Regulation) has already set specific minimum targets for the public truck charging infrastructure in all EU member states. This regulation obliges every EU member state to install a charging station exclusively for heavy goods vehicles at least every 60 to 100 kilometres in each direction of travel by 2030.¹⁹ However, the progress made in achieving these goals varies from country to country.

Germany has developed an extensive fast charging network with over 28,000 DC fast charging stations.²⁰ Milence is actively contributing to this effort with several operational and planned 400 kW charging hubs, ensuring comprehensive coverage and support. However, many existing stations are not optimally designed for trucks, necessitating new dedicated installations to accommodate large vehicle sizes and parking logistics.
The Netherlands boasts a robust fast charging infrastructure with over 4,000 DC fast charging points.²⁰Milence plays a crucial role in this expansion, with existing and planned 400 kW charging hubs enhancing support for electric heavy-duty vehicles. Despite the high number of charging points, the need for truck-specific stations with appropriate spacing and logistics remains a challenge.
France has actively expanded its charging infrastructure to support the transition to electric heavy goods vehicles. The southern European country currently has 22,098 fast charging points, including those capable of delivering 400 kW.²⁰These stations are strategically located to serve major transport routes and logistics hubs, ensuring efficient charging during the mandatory rest periods. Milence, for example, has built a charging hub with four 400 kW stations in Heudebouville. In addition, the joint venture is planning the construction of three further 400 kW stations in Perpignan.²¹However, like Germany and the Netherlands, the infrastructure needs to be tailored specifically for trucks.

To put these figures into perspective: The Netherlands has the highest density of fast-charging stations at around 96 per 1,000 square kilometres, compared to 78 in Germany and 40 in France. This indicates that the Netherlands is more advanced in terms of fast charging infrastructure in relation to its size. However, despite these figures, all three countries still need to expand their networks to fully comply with the AFIR regulations and address the specific spatial and logistical needs of electric trucks.

Energising Europe’s highways: UTA eCharge® supports the electric truck revolution

Europe is making significant strides in building a robust charging infrastructure to support the transition to electric trucks, essential for achieving the ambitious 45 percent CO2 reduction target by 2030. The number of public charging stations has grown but 3.4 million will be needed by 2030. Heavy-duty vehicles require extensive infrastructure, including thousands of high-power chargers. Companies like Milence are spearheading this effort with substantial investments in 400 kW and megawatt charging stations.

To support this transition, UTA Edenred offers the UTA eCharge service as vehicle card, especially for electric trucks, providing access to over 750,000 public charging points across Europe. This service ensures convenient, flexible, and cost-efficient charging for electric fleets, making it an ideal solution for companies.

Electric truck charging infrastructure in Europe