Economics of electric vehicle corridor fast charging in the United States

Borlaug, Brennan; Caristo, Vince; Ouren, Fletcher; Yang, Fan; Wood, Eric; Roberson, Laura

doi:10.1016/j.adapen.2025.100257

Economics of electric vehicle corridor fast charging in the United States

Journal Article · Sat Dec 06 00:00:00 EST 2025 · Advances in Applied Energy

DOI:https://doi.org/10.1016/j.adapen.2025.100257· OSTI ID:3014957

^[1]; Caristo, Vince ^[1]; Ouren, Fletcher ^[1]; Yang, Fan ^[1]; ^[1]; Roberson, Laura ^[2]

National Renewable Energy Laboratory (NREL), Golden, CO (United States)
US Department of Energy (USDOE), Washington, DC (United States)

Corridor direct-current fast charging (DCFC) stations enable long-distance electric vehicle travel, yet their economics remain uncertain due to high capital costs, low initial utilization, and exposure to utility demand charges. This study evaluates the long-term economics of corridor DCFC across the United States, incorporating capital and operating expenses-including charging equipment and real-world utility tariffs-alongside modeled station utilization, financial incentives, and ancillary retail revenue. In the Baseline scenario, modeled breakeven costs for corridor DCFC average $$\$$$$0.42/kWh over 20 years, yet fewer than half of stations reach cost parity with gasoline on a per-mile basis. Utilization is the primary driver of cost variation, with low-utilization stations costing roughly six times more per kilowatt-hour than the national average. Excluding stations that fail to reach cost parity reduces National Highway System coverage within 50 miles from 94% to 67%, underscoring the trade-off between market-driven deployment and comprehensive network coverage. These results provide guidance for charging providers, utilities, planners, and policymakers seeking to develop and sustain a financially viable national corridor charging network.

View Accepted Manuscript (DOE)

Research Organization:: National Laboratory of the Rockies (NLR), Golden, CO (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Vehicle Technologies Office (VTO)

Grant/Contract Number:: AC36-08GO28308

OSTI ID:: 3014957

Report Number(s):: NLR/JA--5400-92119

Journal Information:: Advances in Applied Energy, Journal Name: Advances in Applied Energy Vol. 21; ISSN 2666-7924

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION
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electric vehicle

Economics of electric vehicle corridor fast charging in the United States

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