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Reducing Engine Methane Emissions Up to 50% Through Balancing Operational and Climate-Related Goals
Top Considerations when Combining the Cat® G3600 Gen 2 Kit and CCV System for A4 Gen 1 Engines
Parts & Services
Sustainability
About
Gas compression operators continue to seek new ways to keep pace as the industry evolves. However, implementing new technologies can be daunting for several reasons – especially if downtime is involved.
Leveraging the Cat® G3600 Gen 2 kit with the Cat Closed Crankcase Ventilation (CCV) System allows operators to balance enhancing engine performance while also reducing greenhouse gas (GHG) emissions. This approach offers key benefits that help maintain a lower total cost of ownership for existing A4 Gen 1 assets. Below, Caterpillar Oil & Gas answers operators’ most pressing questions to help further optimize the results experienced with the field-proven G3600 Gen 2 kit when utilized with the Cat CCV System.
Q: I recently upgraded our G3600 A4 engines with a Gen 2 kit. Will my existing engine accommodate the Cat CCV System?
The G3600 Gen 2 kit and Cat CCV System are independent, yet complementary solutions that address different sources of engine methane emissions. The G3600 Gen 2 kit reduces internal combustion methane emissions, while the CCV System captures, filters and combusts the engine’s blow-by emissions.
Efforts to reduce GHG emissions often benefit from a multi-pronged approach that layers multiple technologies. With field-proven solutions designed to synergistically work together, operators can lower GHG emissions without sacrificing throughput.
Q: How much downtime can I expect when installing the upgrades?
For the Cat G3600 engine series, the CCV System can be installed at any time in the field or during a top end, in-frame or major overhaul in approximately 8 to 10 hours[i], with minimal to no change to the compression package. Optimal results are experienced when collaborating with an operator’s Cat dealer, ensuring access to highly skilled technicians trained to expertly apply both upgrades.
Q: Will adding the Cat CCV to my G3600 make a noticeable impact?
The Cat CCV System is an economical option to support gas compression operators’ climate-related targets and is designed to complement the Gen 2 kit’s GHG emission-reduction and optional increased horsepower benefits. When upgrading an A4 Gen 1 engine with a Gen 2 kit and a Cat CCV System, operators can anticipate reducing engine methane emissions by 50% while eliminating blow-by emissions.[ii]
With more than 38,000 engine hours logged as of November 2024 in the Permian Basin and Marcellus Shale, the CCV System offers operators with G3600 assets a reliable approach to decrease GHG emissions.
Q: How will the Cat CCV affect total cost of ownership?
The bolt-on Cat CCV System delivers a range of benefits that help optimize ownership costs and maintain engine reliability. In addition to being easy to service, the Cat CCV offers an 8,000-hour filter service life to further enhance engine uptime and operational efficiency.
The Cat CCV System also significantly reduces the traditional condensation complications often encountered with third-party, off-engine-mounted closed crankcase ventilation systems. Such systems allow crankcase gas to mix with the engine’s oil, which can clog hoses in low-ambient conditions. Third-party systems also can increase the risk of engine component corrosion when condensed gases move through the filtration system.
In contrast, the Cat CCV System’s engine-mounted design allows coolant to circulate around the filtration system to substantially reduce the risk of condensation which helps maintain the engine’s integrity and longevity. When combined with the G3600 Gen 2 kit, operators can further enhance engine performance and efficiency.
Lastly, economically reducing engine methane emissions can help operators decrease the Waste Emissions Charge (WEC) established in the Inflation Reduction Act (IRA) of 2022 and support climate-related targets.
Q: Is a CCV System necessary when purchasing a new G3600 engine?
The Cat CCV System is a standard feature on all new gas compression G3600 A4 Gen 2 engines.
Complementary Upgrades That Optimize Existing Engines
Customized for the gas compression industry, the Cat G3600 A4 Gen 2 kit and CCV System are standalone technologies that seamlessly work together to enhance the overall performance, efficiency and longevity of existing engines. The synergies operators can experience by employing both innovations allow engine methane emissions to be lowered by up to 50% when compared to the G3600 A4 Gen 1 engine performance alone. This dynamic pairing helps ensure operators are equipped to navigate shifting industry requirements.
1. Estimation for the G3606 and G3608; based on an inline engine with two experienced technicians.
2. Based on OEM data, estimated at the end of ring life, pipeline quality gas (85 MN / 905 BTU/ scf)
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