Shipbuilder Senesco Marine LLC, North Kingstown, R.I., has contracted ABB to deliver an integrated hybrid-electric propulsion system for a new 75-car passenger and vehicle ferry ordered by the Delaware River and Bay Authority, the companies announced Tuesday.
The new vessel will replace the 45-year-old Cape Henlopen on the 17-mile Cape May-Lewes route connecting Lewes, Del., and Cape May, N.J. Construction is scheduled to begin at Senesco's yard in mid-2026, with delivery expected in 2029.
ABB said its scope of supply includes its Onboard DC Grid power platform, PEMS power and energy management system, and engineering, acceptance testing, training, and commissioning support. The hybrid-electric configuration is projected to cut fuel consumption by roughly 35% compared with the existing fleet, while also reducing operating and maintenance costs, according to the company.
The vessel will enter service as a diesel-electric ship but is designed to accommodate a 7,000 kWh battery pack for a future upgrade to fully electric, zero-emission operations. Elliott Bay Design Group, Seattle, developed the design, and the vessel will be classed by the American Bureau of Shipping to meet Coast Guard requirements.
The ferry’s cost of $78.6 million is being partially funded with a $20 million grant from the Department of Transportation's 2024 program, which allocated $300 million nationwide to support hybrid and electric ferry upgrades. It is also subject to Buy America rolling stock requirements under 49 CFR 661.
Established in 1964, the Cape May-Lewes Ferry has carried more than 50 million passengers and supports more than 4,000 regional jobs tied to hundreds of millions of dollars in annual economic activity.
"Senesco Marine is truly excited to have been awarded the DRBA contract for the Cape May Lewes Ferry. We are absolutely thrilled to be working alongside ABB on this project, especially given their remarkable expertise and proven success in the hybrid propulsion space," said Ted Williams, president of Senesco Marine.
"ABB is proud to support the modernization of the Cape May–Lewes Ferry with hybrid-electric propulsion technology developed and supported here in the United States," said Timo Vesala, head of sales, Marine Systems, Americas, for ABB's Marine & Ports division. "This project builds on our long-standing commitment to helping American shipyards and coastal communities move toward cleaner, more efficient marine transportation. Our solutions are entirely scalable, and our ferry projects range from the biggest electrification programs to smaller vessels with very tailored needs."
ABB secured a similar contract in December 2025 to supply hybrid-electric propulsion systems for two 160-auto ferries for Washington State Ferries as part of that operator's System Electrification Program.
