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Port Newark Container Terminal is one of the biggest in the United States, and therefore needs dozens of terminal tractors to keep up with the influx of cargo delivered by ships from around the world.
The power provided by its fleet of terminal tractors to move all those containers is one thing. Sustainability is another. Instead of electric terminal tractors, officials at Port Newark Container Terminal (PNCT) opted for propane models to dramatically reduce emissions, thus enhancing conditions for workers and surrounding communities.
PNCT deployed 20 near-zero-emission propane terminal tractors from German firm MAFI in the first quarter of 2024, and isn’t looking back. The entire fleet of 45, currently including 25 diesel models, should be fully propane-powered by mid-2025.
Significantly Lower Emissions
PNCT operates on 272 acres in Port Newark, New Jersey. Its annual throughput is more than 1.6 million TEUs, or Twenty-Foot Equivalent Units. In other words, that’s a lot of cargo, according to Charlie Ferlisi, PNCT director of engineering and equipment services. Ferlisi said multiple fuel options were considered for meeting PNCT’s sustainability objectives.
“Electric terminal tractors were tested,” he said. “Unfortunately, we were not able to get promising results on the battery life due to our longer operating hours, operating on a 5% incline and colder climate temperatures in the winter months.”
Propane terminal tractors were also tested and ultimately selected, and the numbers validate that decision. For example, the new terminal tractors yield 99% fewer nitrogen oxide (NOx) composite and idle emissions than diesel models, Ferlisi said. “It is undoubtedly a much healthier, cleaner and environmentally sustainable solution for the workers and adjacent communities.”
Extensive Environmental Testing
Deploying PNCT’s propane terminal tractors was a process unto itself and was thoroughly carried out. PNCT partnered with MAFI to design and engineer the 20 tractors in use today. Once a concept design was mutually agreed upon, a prototype unit was built and tested onsite for several months.
“We went through extensive endurance and environmental testing to ensure that the tractors were able to meet both the terminal’s operational and sustainability goals,” Ferlisi said.
Emissions testing was performed by a third-party firm that captured live data comparing propane terminal tractors to diesel. In addition to the 99% NOx reduction, they produce 77.5% fewer total hydrocarbon (THC) idle emissions, 14% fewer brake-specific carbon dioxide emissions and 75% fewer total particulate matter (TPC) emissions compared with diesel.
Seamless Propane Fueling
With the assistance of propane provider Suburban Propane, PNCT was able to design and create a 3,000-gallon mobile tank. The design was created so that fueling could be conducted at the designated terminal tractors’ parking area. A travel route was implemented and approved by the New Jersey Department of Community Affairs.
“This has helped us safely refuel the terminal tractors and eliminate downtime,” Ferlisi said. “Suburban Propane is delivering propane to the storage tank weekly.”
Validation of the success of PNCT’s propane terminal tractors has come from many avenues, including the Propane Education & Research Council, which awarded PNCT with its Energy for Everyone Hero Award at a special ceremony in late July 2024.
“Its meaning symbolizes the continued dedication and commitment PNCT has to decarbonize by finding sustainable solutions,” Ferlisi said. “We continue to strive to find cleaner solutions for our workers and the surrounding communities.”
Learn more about how propane powers ports.
