Region 1: EPA New England
Sustainable Ports: Cargo Handling Equipment
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Retrofit
Purpose
Retrofit (after treatment) technologies can reduce emissions by adding a new, cleaner technology to an older system. Technologies available for cargo handling equipment include Selective Catalytic Reduction (SCR), Diesel Particulate Filter (DPF), CCV Closed Crankcase Ventilation (CCF), Exhaust Gas Recirculation (EGR), and Diesel Oxidation Catalyst (DOC). These devices do not improve fuel economy, but can be cost-effective means of reducing impacts on port workers, neighbors and ambient air quality.
EGR: Recirculates a portion of exhaust back into engine to cool peak combustion temperatures and reduce NOx.
CCV: Provides a cleaner engine environment by capturing and returning oil in blow-by gasses to the tank. VOCs are sent to intake system for re-combustion rather than sent out as exhaust. PM is collected in a filter and removed from crankcase vapors.
SCR: injects urea (or other form of ammonia) into the exhaust stream to react this mixture over a catalyst, reducing NOx emissions.
DOC: oxidizes pollutants in the exhaust stream; can be packaged with the muffler.
DPF: mesh or honeycomb device placed within the exhaust stream to trap and oxidize PM.
Location & Projects
Port of Seattle: all eligible CHE has been retrofitted with DOCs
Port of Cleveland: cranes and forklifts have been retrofitted
Port of Boston: cranes and yard tractors have been retrofitted
Port of Long Beach: hundreds of CHE have been retrofitted
Port of Tacoma: straddle carriers have been retrofitted
Port of LA: hundreds of CHE have been retrofitted
Companies
Companies offering EPA-verified retrofit devices
CAT catalyzed converter mufflers (PDF) (2 pp, 83K, about PDF)
Engelhard - CMX Catalyst Muffler
Lubrizol Engine Control Systems - AZ Purimuffler, AZ purifier
Johnson Matthey - CEM Catalyst Converter, DPF
Cleaire – DPF
Clean AIR Systems – DPF
Pollution Reduction
Port of Seattle: DOCs reduce PM by 20%, HC by 50%, CO by 40%
Port of Cleveland: DOCs reduce PM by 20%, HC by 50%, CO by 40%
Port of Boston: DOCs reduce PM by 20%, HC by 50%, CO by 40%
Port of Long Beach: 79 tons NOx/year, 16 tons PM/year
Port of Tacoma: DOCs reduce PM by 50% with ULSD, 1 ton of sulfur/year
Port of LA: DOCs reduce PM by 25%
For average pollution reductions by device type, see EPA Clean Ports USA
Cost
DPFs: $5,000-$8,000/unit
DOCs: $1000-$4000/unit
Grants
Port of Boston: EPA: $83,000
Port of Long Beach: EPA & CARB: $2,000,000
Comments
EPA and the California Air Resources Board (CARB) verify retrofit technologies.
The Diesel Technology Forum provides information on retrofit devices (and other technologies and fuels)
Western Region Air Partnership DOC retrofit project report (PDF) (8 pp, 105K, about PDF)
CCV filters need to be changed regularly.
DPFs must be paired with ULSD.
Repair, Rebuild, Repower
Purpose
It can be cost-effective to replace, rebuild, or repower a piece of cargo handling equipment rather than replace it. Repowering means modifying or replace an existing engine with a cleaner, more efficient technology of the same type, or with an alternative-fuel engine. Rebuilding an engine involves taking it apart, cleaning and adjusting components, and replacing/upgrading components to new standards. Rebuilding an engine can significantly lower emissions and can be cost effective for equipment that is costly to replace.
Properly maintaining and repairing engines can save fuel, reduce emissions and extend engine life.
Location & Projects
Port of Long Beach: repowered 3 yard hostlers
Port of Virginia: rebuilt several engines on RTG cranes
Port of Oakland: repowered 70 heavy-duty vehicles
Cost
Average cost to repower a truck: $21,500
Port of Oakland project: total cost $1.5 million
Grants
Long Beach yard hostlers: EPA $75,000, CALSTART/Westart $525,000
Port of Oakland: received Carl Moyer funding
Port of Houston Authority: $150,000 in EPA funding
Comments
Port of Oakland's project was never finished – seen as restrictive by some.
Hybrid or Electric Straddle Carrier
Purpose
Straddle carriers can be run as hybrid diesel/electrics or purely on electricity, both of which save fuel and reduce emissions in port areas.
Location & Projects
Port of Tacoma: 7 Kalmar CSC 340 straddle carriers
Companies
Hybrid or Electric Forklift
Purpose
Electric and hybrid forklifts transport goods quickly and reduce worker exposure to emissions from fuel combustion. Hybrids can save fuel.
Location & Projects
Many terminals use electric forklifts; suitability of any type/make/model is dictated by terminal operations rather than ports.
Cost
An electric forklift manufacturer claims that each unit will save $700-$1,000 per year due to fewer wearable parts, longer service intervals, and lower energy cost.
Hybrid or Electric Reach Stacker
Purpose
Reach stackers move incoming, dwelling and outgoing cargo around ports. Electric and hybrid diesel/electric motors reduce emissions and allow for cleaner-running machines.
Location & Projects
Cost
One manufacturer claims that each unit will save $700-$1,000 per year due to fewer wearable parts, longer service intervals, and lower energy cost.
Hybrid or Electric Yard Hostler/Tractor
Purpose
Hybrid and all-electric yard hostlers operate efficiently under stop & go conditions and reduce on-dock emissions.
Location & Projects
Port of LA: 20 electric yard hostlers, 5 on-road electric short-haul drayage trucks
Pollution Reduction
Long Beach hybrid yard hostlers reduce NOx and PM by 93% (compared to diesel-only yard hostlers). Kalmar Industries will integrate hybrid drive system into Ottawa 4x2 yard tractor
Port of LA: Electric_Truck_Demonstration Project Fact_Sheet (PDF) (3 pp, 36K, about PDF)
Cost
Balqon Corporation stated that an electric yard hostler saves $.60-$1.60/mile depending on the efficiency of the diesel-fueled vehicle it replaces.
At $190,000 to $210,000 per unit, electric yard trucks can cost approximately three times what a diesel-fueled unit would cost, and about twice what propane or natural gas –fueled units cost.
Grants
Long Beach Yard Hostlers: $300,000 from EPA matched by $900,000.
LA yard hostlers: South Coast Air Quality Management District and Port of LA contributed $527,000 for testing this technology.
Hybrid or Electric Crane
Purpose
Both hybrid diesel-electric and all-electric cranes improve air quality and save fuel. Hybrid motors capture and store energy generated by deceleration and gravitational pull, and later provide it for acceleration and hoisting.
Location & Projects
Pollution Reduction
Vycon hybrid crane reductions of >25% PM, 30% NOx, 35% CO2
Cost
Railpower hybrid RTG crane: 70% fuel savings
Vycon hybrid crane: 30% fuel savings
Georgia Port Authority converted all ship-to-shore cranes to electricity for a total of $4.7 million in 2003.
Grants
Vycon Flywheel at POLA and POLB: $8,000 from AQMD
Comments
Link between ZPMC and VYCON's REGEN system
Every container crane at the Port of Seattle has been converted to run on electricity.