Top Three Benefits of Closed Crankcase Ventilation Systems (CCV) for Gas Compression Operators

As gas compression operators face increasing requirements to lower greenhouse gas (GHG) emissions, closed crankcase ventilation systems (CCV) are a tried-and-tested solution to address these evolving needs. Used for decades, CCV systems help eliminate the venting of crankcase gases, also known as blow-by emissions, by capturing, filtering and combusting the gases to reduce atmospheric emissions.

Operators can realize three important benefits when utilizing an OEM-designed CCV system for the Cat® G3600: reduced engine methane emissions, convenient installation and reliable operation at low ambient temperatures.

Lower Methane Emissions

Regulatory bodies in the U.S. and other jurisdictions have placed greater focus on lowering methane emissions. One of the most significant benefits a CCV system provides is the ability to prevent the unintentional release of methane emissions from an engine’s crankcase. By eliminating blow-by emissions, a Cat CCV System offers a robust solution that helps gas compression operators economically lower methane emissions, reducing the Waste Emissions Charge (WEC) established by the Inflation Reduction Act (IRA) and supporting climate-related goals.1

By eliminating blow-by emissions, a Cat CCV System offers a robust solution that helps gas compression operators economically lower methane emissions. This reduction can help decrease the Waste Emissions Charge (WEC) established in the Inflation Reduction Act (IRA) of 2022 and support sustainability goals.

With the Cat CCV System, operators can reduce engine methane emissions by up to 20%, which can translate into substantial cost savings.2 The integrated Cat CCV System is field proven in the Permian and Marcellus basins, with 33,000 engine hours logged to date.3

The U.S. Environmental Protection Agency (EPA) Greenhouse Gas Reporting Program (GHGRP) released final amendments in May 2024 that revise the program’s emission data reporting and add new emissions source calculations.4 The changes require crankcase emissions to be quantified but allow for the manufacturer’s data to be used. An engine equipped with a Cat CCV System simplifies the regulatory reporting process as it’s a closed loop system that eliminates the need to measure and report methane emissions from the crankcase.

A CCV System that Maintains Engine Reliability

The Cat CCV enhances operators’ assets in crucial ways:

  • Improved Engine Oil Consumption – Filtering oil mist and debris from crankcase gases allows filtered oil to be returned to the engine oil sump. This not only reduces engine oil consumption but also helps prevent engine and catalyst damage as well as facility contamination, fostering a cleaner, safer working environment.
  • Elimination of Condensation - Conventional third-party CCV systems that are mounted off-engine can be prone to condensation. In low ambient conditions, crankcase gas can condense and subsequently mix with oil, which can potentially impact lube oil performance and clog a CCV system's hoses. Additionally, condensed gases that pass through the filtration system could corrode engine components. Such scenarios can cause unplanned downtime, additional maintenance and costly engine damage.

    In contrast, the Cat CCV is engine mounted, which allows a heated coolant to circulate around the filtration system. When combined with external insulation, this helps eliminate condensation.
  • Crankcase Pressure Management - The Cat CCV electronic control valve connects to the system’s electronic control module to manage crankcase pressure in real-time. This ensures consistent, healthy pressure inside the engine crankcase which promotes engine durability.

Cost Effective and Easy to Install

It’s critical for gas compression operators to minimize downtime. Fortunately, existing Cat G3600 engines can be upgraded quickly with a Cat CCV System in the field or in the shop within a few hours.5

The Cat CCV System directly mounts onto the engine without the need for complex rigging or modifications. The “bolt-on” design eliminates the need for machining or welding, resulting in less complex and labor-intensive installation. The system typically requires minimal changes, if any, to the compression package, which helps mitigate operational disruption. In contrast, many conventional CCV systems install onto a secondary structure or rig that hangs off the engine, which may require extensive labor and can lead to longer downtime.

The filters inside the Cat CCV System are easy to service and offer an 8,000-hour service life, further enhancing engine uptime and operational efficiency.

The Cat CCV system provides a cost-effective, field-proven approach to lower methane and other GHG emissions without compromising engine performance or uptime. Overall, a CCV system is a valuable option to help gas compression operators meet both performance and climate-related objectives while adapting to evolving industry requirements.

1. EPA. “Waste Emissions Charge”. https://www.epa.gov/inflation-reduction-act/waste-emissions-charge
2. Site conditions: G3608 A4 engine, 0.3g/bhp-hr NOx, 8,760 hours/year, $1,500/metric ton methane fee, 24 hours labor times two technicians to install CCV system and package changes, service cost.
3. Caterpillar Oil & Gas Cat Closed Crank Ventilation (CCV) System Press Release; Data as of September 2024.
4. EPA. “Rulemaking Notices for GHG Reporting”. https://www.epa.gov/ghgreporting/rulemaking-notices-ghg-reporting
5. New Cat G3600 A4 engines are equipped with CCV technology as a standard feature starting in 2025

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