Your Questions Answered: Closed Crankcase Ventilation Systems for Reciprocating Gas Compression Engines

Basics and Benefits of Selecting a System to Reduce Engine Methane Emissions

Gas compression operators must balance a range of considerations when deciding which crankcase ventilation system (CCV) to select to manage increasingly stringent emissions requirements. Different systems can benefit operators in mitigating the venting of unwanted gases such as the gases emitted from a high-performance engine’s crankcase. This quick guide covers basic CCV features to consider, and the benefits of choosing the right closed CCV system to help lower emissions to achieve climate-related objectives.

What is Crankcase Ventilation?

Crankcase emissions can result from air-fuel mixture and combustion by-products escaping into the engine crankcase via piston rings. These escaping fumes are commonly called blow-by. If not controlled, an engine’s blow-by can contaminate the lubricating oil and pressurize the crankcase, possibly leading to an oil leak.1

In a typical engine operation, blow-by gases are vented to the atmosphere using a special venting system, which can result in substantial methane emissions as well as a loss of engine lube oil which can cause facility contamination. With increased focus on reducing GHG emissions and operational efficiency, gas compression operators are seeking technologies to eliminate venting crankcase gases. Accomplishing this requires the use of a CCV system.

What is a CCV System?

A crankcase ventilation system captures, filters and combusts the engine’s blow-by emissions, which are a mixture of air and unburned fuel as well as combustion gases. This helps protect the engine by releasing excess pressure and fumes while also extracting contaminants such as oil mist, which can impact an engine’s lubrication system and increase its oil consumption.

CCV systems are designed to control the balance of air pressure between the engine crankcase and atmospheric pressure while processing the accompanying fumes. Crankcase air pressures that are excessively above or below atmospheric pressure can effect component life, the lubricating oil system and overall engine emissions. Venting the engine crankcase is not a difficult process in itself. However, controlling emissions and preventing contamination add some complexity.

CCV systems promote engine health and support equipment longevity to help avoid costly downtime. Operators can enhance efficiency and address evolving requirements related to methane emissions by choosing the right system based on site conditions, compression package and other factors.

Why are CCV Systems Effective in Lowering Emissions?

A CCV system is a closed loop system that moves gas from engine crankcase to engine intake system through a filtration system. This process enables the CCV system to eliminate the venting of crankcase gases to the atmosphere.

The Cat® CCV System for G3600 engines reduces methane emissions by up to 20%. Its ease of installation and affordability make it an economical option to support climate-related targets. The CCV system simplifies the regulatory process as it eliminates the need to measure, track and report crankcase emissions. Additionally, the CCV system’s filtration unit separates the lube oil mist from crankcase gas which is then drained back to the engine oil sump. This not only reduces lube oil consumption but also prevents facility contamination.

Solving Condensation Issues with the Cat CCV System

With a conventional CCV approach, cooled ambient air surrounding the CCV system can lead to condensation of the crankcase gas inside the CCV system. The condensed crankcase gas could potentially mix with filtered lube oil, which can lead to clogging and compromised filters. This could potentially cause unplanned downtime, increased maintenance and even engine damage.

The Cat CCV system is specifically designed to address these condensation challenges and is a reliable solution to help operators maximize uptime and lower total cost of ownership. Unlike conventional CCV methods, the Cat CCV System holds multiple unique patents that allow the system to prevent moisture-related clogs in tubes, hoses and filters.

Designed specifically for Cat G3600 solutions, the Cat CCV system is a field-proven technology designed to eliminate the venting of crankcase gases while also mitigating condensation even in low ambient temperatures. When combined with the G3600 Gen 2 retrofit kit, operators can further support their climate-related objectives. The system eliminates blow-by emissions,2 and it typically involves minimal to no change to the compression package.

As gas compression operators continue to prioritize efficiency and reliability, it’s essential to consider the changing methane emissions requirements as well as individual climate-related objectives. Solutions like the bolt-on Cat CCV system can deliver a range of benefits by supporting engine health, lowering oil consumption and eliminating the venting of blow-by emissions.

1. Application & Installation Guide: Crankcase Ventilation Systems. PON Cat. https://www.pon-cat.com/application/files/6115/8461/6004/LEBW4958-05_Crankcase_ventilation.pdf
2. Site conditions: Cat® G3608 A4, .3g/bhp.ht NOx, 8,760 hours/year, $1,500/mTon methane fee.wo technicians to install CCV system and package changes, service cost.

G3616
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Pictured is a G3616 A4 Gen 2 Engine with CCV with no insulation.

Gas Compression Engine
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