Optimizing series hybrid truck performance with synthetic Fuels: From engine testing to vehicle simulation

Decarbonizing heavy-duty transport requires balancing environmental impact, performance, and feasibility. This study investigates combining a synthetic oxygenated fuel blend (85% diesel, 15% OMEx) with a series hybrid powertrain to cut tailpipe and life-cycle CO 2 emissions. Engine tests on a single-cylinder platform explored drop-in, iso -load, and optimized calibrations. The optimized strategy exploited OMEx’s oxygen content, reducing soot by over 50% and NOx significantly, while maintaining competitive fuel efficiency. These results were integrated into a vehicle simulation of a medium-duty hybrid truck under regulatory drive cycles. Optimization of battery size and energy management showed that mid-sized packs (∼45 kWh) maximize tank-to-wheel CO 2 reductions without excessive mass. Life cycle analysis indicated 15–30% CO 2 savings for series hybrid, with optimized control outperforming simpler strategies. Compared with diesel, battery-electric trucks halved life-cycle CO 2 but required large 300 kWh batteries, increasing weight and limiting range (250 km vs. 700 km). Although Battery Electric Vehicles offer the lowest tailpipe emissions, their mass and infrastructure demands limit short-term applicability. Conversely, hybrids using diesel/OMEx retain conventional range while delivering meaningful CO 2 cuts. This integration offers a pragmatic, near-term pathway to decarbonize medium-duty transport until large-scale electrification becomes viable.