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Most diesel engines can be converted to natural gas. Although very large locomotive, marine, or genset engines are costly and time
consuming to convert, the rate of return makes a DNG engine conversion always a viable solution. On the other side of the spectrum, small passenger vehicle diesel engines are very difficult to convert and do not offer a favorable cost-benefit ratio.
The Omnitek diesel-to-natural gas conversion technology is matured and used around the world. The system converts an existing diesel engine into a clean burning natural gas engine (CNG, LNG or RNG) at a fraction of the cost of a new engine. Natural gas is a superior fuel for many reasons such as lower fuel cost and lower emissions.
We are the only company with multiple EPA approved Class 8 heavy-duty diesel-to-natural-gas conversion kits available, that has also achieved Euro 6 emissions levels.
Omnitek's proprietary technology overcomes past problems of unreliability and poor performance found in the first generation of natural gas engine technology.
Omnitek's technology outperforms competitors in side-by-side comparisons in all relevant areas, including cost, efficiency, performance, emissions, and reliability.
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No. Omnitek has the technology to convert many different engine brands and models.
Popular engines Omnitek has converted are: Cummins, Detroit Diesel, Caterpillar, and Navistar in the USA, Mercedes, Volvo, MAN, and Cummins in Europe, and Isuzu, Hino, Nissan, and Mitsubishi in Asia. In addition to
the above mentioned markets, Omnitek has converted most engine brands found in Mexico, South America, and China.
Our conversion technology can be used to convert most diesel engines, such as those used in trucks and city buses. We also convert locomotives, marine applications, power generators, pumps, and other stationary engines.
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Omnitek has validated the diesel-to-natural gas engine conversion technology with over 5,000 engine conversions worldwide.
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DNG engine power is about 28hp to 35hp per 1 Liter of engine displacement. Therefore, depending on engine model, a 10 liter engine can make up to 350hp.
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Why discard a vehicle early and buy a natural gas vehicle? Natural gas vehicles are VERY expensive. Diesel engines have a long service life and are overhauled on a regular basis. The difference in cost to convert the diesel engine to natural gas, rather
than overhaul the diesel engine, is minimal.
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All Omnitek DNG Engines can be used with either compressed natural gas (CNG), liquid natural gas (LNG), or renewable natural gas (RNG or Biogas).
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RNG offers very low greenhouse gas emissions (GHG or CO2) and its use may qualify for tax incentives or credits.
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The maintenance intervals and procedures are the same as on any other natural gas engine and vary depending on the engine model and application.
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Don't wait for government subsidies to convert. Do it sooner rather than later. If you use $4000 of diesel fuel per month and save $2000 of that when using natural gas, you will have paid for a $30,000 conversion after only 15 months and a $50,000 conversion in only 25 months.
However, some heavy-duty diesel trucks, such as used for trash collection and city buses, use so much fuel that the payback period can be
as short as 6 months. The same is true for power generators.
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Due to reliability issues and low money savings potential, Omnitek does not support this technology. We only offer conversions to 100% natural gas.
If you consider a diesel replacement of 50%, and the cost of natural gas is 50% of diesel, the money saved is only 25%. Now consider that the cost of natural gas may only be 30% under the cost of diesel - the money saved is only 15%.
You also have to carry two fuels and make two trips to the gas station.
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Pre-conversion
A pre-conversion inspection determines the condition of the vehicle/engine. Additional work may be needed as part of the conversion.
Consulting with customer:
1- Determine who will perform the conversion/engine swap.
2- Document the condition of the vehicle/engine.
3- Discuss how much time the conversion will take.
5- Discuss any possible power loss during conversion.
6- Will the conversion be CNG or LNG?
7- What is the driving range requirement?
8- What tanks will be used, Type 1, Type 2, Type 3 or Type 4?
9- Is there space for the gas tanks and how are they mounted?
Conversion
The conversion time will be determined based on the number of
vehicles/engines being converted and manpower associated to the process.
Vehicle Conversion Process:
1- Disassemble the engine.
2- Check all components and replace accordingly.
3- Install CNG pistons.
4- Modify cylinder head for spark plugs.
5- Install high-temp valves and valve seats.
6- Install engine sensors.
7- Install natural gas injectors and ignition system.
8- Reinstall engine.
9- Install natural gas fuel system incl. tanks and fuel lines.
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The Omnitek DNG Engine Limited Warranty is 3 years/100,000 miles/2,000 hours, whichever comes first.
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Cost of the conversion is based on the engine model as well as where the engine will be operated. Engines operated in EPA/CARB regulated markets are more expensive
to convert than engines operated in foreign and non EPA/CARB regulated markets. The cost to convert an engine is minimally higher than a straight diesel engine overhaul.
Please call our office with your engine model and requirements and we will gladly assist you in creating a quote.
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The Omnitek DNG engine is no different than the any OE natural gas engine. The system can be optimized for any climate or altitude.
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As with all natural gas engines, high-load operations in steep or mountainous terrain is not an optimal application.
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This is not a yes or no answer, since diesel engines come in many different power levels (same engine model).
If we consider a Cummins B 5.9 - it comes in 175hp, 190hp, 210hp and 230hp. We can keep the power to 175 and 190, but over 200 the thermal load is too much.
The best way is to consider that for every 1 liter engine displacement we can reliably make 28 - 35hp. This means that on some engines we derate power by 10% - 15%. On gensets the power loss is greater.
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In general, starting from a stand still may need some getting used to it, as low-end torque is a bit less and is moved up the rpm range slightly, by about 100 – 150 rpm.
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It depends a lot on the engine and the application, but it is no different than any OE natural gas engine.
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Yes, natural gas engines have to use low-ash engine oil. If diesel engine oil is used, severe engine damage can result.
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Omnitek uses in-house designed, natural gas optimized internal combustion engine components/materials.
This includes pistons and rings, as well as hardened valves and valve seats
for high-temperature operation.
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Integration is challenging, especially without OE support. The Omnitek ECM uses the industry standard protocols J1939 and J1587 to communicate with OE control modules and systems,
so all readouts and control functions can be performed and controlled by the Omnitek ECM.
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Omnitek does offer training on the natural gas converted engine and performance characteristics of the vehicle to drivers and service technicians.
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The Omnitek staff is keenly aware of available incentives for natural gas projects and is more than willing to assist fleets with their requirements.
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A diesel-to-natural gas engine conversion is not unlike an engine overhaul and takes about the same amount of time. The engine is completely disassembled and all components checked. Any component out of spec is replaced.
The engine is reassembled and in the process converted to natural gas, resulting in a drop-in ready, as-new natural gas engine.
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Depending on the size of the project, engine model and availability of core engines, lead time varies between 1 - 4 months.
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Omnitek works with most CNG and LNG fuel system suppliers and can assist fleets to choose the right solution and supply the system that fits the fleet's
requirements. The installation of the fuel system is generally performed by specialized companies, or by an Omnitek Authorized Installation Center (AIC).
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As with all natural gas engines, the Omnitek DNG engine has essentially no particulate emissions (PM or “black smoke”). Also, it is a well known fact that natural gas has up to 20% lower CO2 emissions than diesel.
The Omnitek DNG engines have CO, HC, PM and NOx emissions all within required limits, and can be delivered with EPA/CARB or European emissions certification.
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The Omnitek natural gas converted engines are not equipped with Jake Brakes. We recommend using another form of brake assist, such as an
electric or hydraulic Retarter.
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Optimally, the fuel tanks are sized so the vehicle can operate one full day per fill-up. On some vehicles this is not possible and a natural
gas conversion is not a good solution for this vehicle and application.
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At this time, we are only working with heavy-duty trucks and buses, not gasoline cars or small diesels.
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Most diesel engines can be converted to natural gas. Although, very large locomotive, marine, or genset engines are costly and time consuming to convert.
However, a short payback period makes a DNG engine conversion always a viable solution.
