If you’re wondering if you can convert a diesel generator to natural gas, the answer is yes, but it’s not as straightforward as you might think. While it is possible to convert a diesel generator to run on natural gas, you’ll need to install an adapter between the gas supply and the carburetor. The adapter combines the natural gas vapors into the air stream above the carburetor. In most cases, you do not need to modify the generator’s carburetor.
However, there are some issues to consider when converting a generator to natural gas. One of the main issues is efficiency. Natural gas is not as energy-dense as other fuels, so generators may not be able to produce as much power when running on natural gas. This means that you may need a larger generator or multiple generators to get the same amount of power as a diesel generator.
Another issue to consider is availability. While natural gas is generally cheaper than diesel, it may not be available in all areas. You’ll need to check with your local gas company to see if natural gas is available in your area and how much it will cost. Additionally, you’ll need to factor in the cost of the adapter and any other modifications that may be necessary when converting your generator to natural gas.
Understanding Diesel and Natural Gas Generators
If you’re considering converting your diesel generator to run on natural gas, you should first understand the differences between diesel and natural gas generators.
Diesel generators are commonly used for standby power, backup power, and in remote locations where there is no access to the power grid. They are typically more fuel-efficient and have a longer lifespan than gas generators. Diesel engines are also known for their reliability and durability.
On the other hand, natural gas generators are often used in commercial and residential settings where there is access to a natural gas line. They are quieter and cleaner than diesel generators and produce fewer emissions. However, they are less fuel-efficient and may require more maintenance than diesel generators.
When it comes to converting a diesel generator to run on natural gas, it’s important to keep in mind that natural gas engines are designed differently than diesel engines. Natural gas engines require a different air-to-fuel ratio and ignition timing than diesel engines.
Additionally, converting a diesel generator to run on natural gas may not always be cost-effective. The conversion process can be expensive and may require additional maintenance and repairs. It’s important to weigh the costs and benefits before making a decision.
Conversion Basics
If you’re wondering whether you can convert a diesel generator to run on natural gas, the answer is yes. However, there are a few things you need to know before you get started.
First, you will need a conversion kit. Conversion kits are available for purchase online or at some hardware stores. These kits typically include an adapter that makes it possible to operate low-pressure propane, natural gas, and gasoline.
The adapter is installed between the gas supply and the carburetor. It combines the natural gas vapors into the air stream above the carburetor. In most cases, you do not need to modify the generator’s carburetor.
When installing the conversion kit, you will need to remove the existing carburetor and replace it with the adapter. The kit should come with all the necessary mounting bolts, fittings, and choke levers.
Once the adapter is installed, you will need to connect it to the natural gas supply. This can be done using copper tubing and a compression ball valve. The copper tubing should be cut to the appropriate length and secured with a hose clamp.
Finally, you will need to adjust the air/fuel mixture and idle speed to ensure that the generator runs smoothly on natural gas. This may require some trial and error, but most conversion kits come with detailed instructions to help you through the process.
Components Involved in Conversion
Converting a diesel generator to run on natural gas involves several components that work together to ensure the engine runs smoothly and efficiently. Some of the components involved in the conversion process include:
Regulator
The regulator is responsible for controlling the flow of natural gas into the engine. It ensures that the pressure and flow rate are within the required range to prevent damage to the engine.
Carburetor
The carburetor is responsible for mixing the natural gas with air before it enters the engine. It ensures that the fuel-air mixture is within the required ratio for efficient combustion.
Valve
The valve is responsible for controlling the flow of natural gas into the carburetor. It ensures that the carburetor receives the required amount of fuel for efficient combustion.
Spark Plugs
The spark plugs are responsible for igniting the fuel-air mixture in the engine’s combustion chamber. They ensure that the combustion process is efficient and produces the required amount of power.
Air Filter Box and Air Filter
The air filter box and air filter are responsible for filtering the air that enters the engine. They ensure that only clean air enters the engine, preventing damage to the engine’s internal components.
Hose
The hose connects the natural gas supply to the regulator. It ensures that the natural gas flows smoothly and efficiently to the engine.
Tank
The tank stores the natural gas before it enters the engine. It ensures that there is a constant supply of natural gas to the engine.
Gas Meter
The gas meter measures the flow rate of natural gas into the engine. It ensures that the engine receives the required amount of fuel for efficient combustion.
Throttle Body and Mechanical Throttle Body
The throttle body and mechanical throttle body are responsible for controlling the engine’s speed. They ensure that the engine operates at the required speed for efficient power generation.
ECM and Camshaft Sensor
The ECM and camshaft sensor work together to control the engine’s timing and fuel injection. They ensure that the engine operates efficiently and produces the required amount of power.
Types of Gaseous Fuels
If you’re considering converting your diesel generator to run on natural gas, you should know that there are several types of gaseous fuels available. Here are some of the most common ones:
Natural Gas
Natural gas is a fossil fuel that is primarily composed of methane. It is a popular choice for powering generators because it burns cleanly and is widely available. Natural gas can be supplied to your generator through a utility pipeline or stored in tanks on-site.
Propane
Propane is a byproduct of natural gas processing and crude oil refining. It is a clean-burning fuel that is commonly used for heating and cooking. Propane can also be used to power generators and can be stored in tanks on-site.
Compressed Natural Gas (CNG)
Compressed natural gas (CNG) is natural gas that has been compressed to a pressure of 3,600 psi or higher. It is typically stored in high-pressure tanks and is used to power vehicles and generators.
Liquefied Natural Gas (LNG)
Liquefied natural gas (LNG) is natural gas that has been cooled to a temperature of -260°F (-162°C) and converted to a liquid state. It takes up less space than natural gas in its gaseous state and is commonly used for transportation and power generation.
Renewable Natural Gas (RNG)
Renewable natural gas (RNG) is a form of natural gas that is produced from organic waste sources such as landfills, wastewater treatment plants, and agricultural waste. It is a sustainable fuel source that can be used to power generators and reduce greenhouse gas emissions.
Methane
Methane is the primary component of natural gas and is a potent greenhouse gas. It can be produced from organic waste sources and used as a renewable fuel source. Methane can also be used to power generators, but it requires special equipment and safety precautions.
Cost Analysis of Conversion
Converting a diesel generator to natural gas can be a cost-effective solution for businesses and individuals looking to reduce their fuel costs and improve sustainability. However, the process requires investing in new equipment and learning new techniques, which can be expensive. Additionally, the conversion may not be perfect, leading to problems with the generator’s performance or emissions.
The cost of converting a generator to natural gas can vary depending on several factors, including the size and type of generator, the availability of natural gas in the area, and the cost of the conversion kit. On average, a conversion kit for a small generator can cost around $500, while larger generators may require a kit that costs up to $10,000.
In addition to the cost of the conversion kit, there may be additional costs associated with the conversion process, such as labor costs for installation and maintenance. It is important to factor in these costs when considering the overall cost-effectiveness of the conversion.
Despite the initial costs, converting a diesel generator to natural gas can make economic sense in the long run. Natural gas is generally less expensive than diesel fuel, which can result in significant savings on fuel costs over time. Additionally, natural gas is a cleaner-burning fuel, which can lead to lower emissions and reduced environmental impact.
Performance and Efficiency After Conversion
After converting your diesel generator to natural gas, you may be concerned about its performance and efficiency. It’s important to note that natural gas is not as energy-dense as diesel, so your generator may not be able to produce as much power when running on natural gas. However, newer and more efficient generators can overcome this problem.
In terms of efficiency, natural gas is a cleaner-burning fuel than diesel, so you can expect a reduction in emissions and lower fuel costs. The use of natural gas as a fuel in power generation reduces fuel cost of power per unit, and therefore conversion from use of diesel to natural gas can be used as a strategy to reduce the high cost of diesel power generation.
It’s also worth noting that the conversion process itself can affect the performance and efficiency of your generator. A proper conversion process will ensure that your generator runs smoothly and efficiently, while a poorly executed conversion can lead to decreased performance and efficiency.
To ensure the best performance and efficiency after conversion, it’s recommended to use a tri-fuel conversion kit from a reputable manufacturer. This kit allows your generator to run on natural gas, gasoline, and propane, giving you more flexibility in fuel options.
Emission Considerations
When considering converting your diesel generator to run on natural gas, one important factor to consider is emissions. Natural gas is considered a cleaner-burning fuel compared to diesel, but it still produces emissions that can have an impact on the environment and human health.
The main pollutants produced by natural gas generators are nitrogen oxides (NOx) and carbon monoxide (CO). NOx is formed when nitrogen in the air combines with oxygen during combustion, and it can contribute to smog and acid rain. CO is a colorless, odorless gas that can be deadly in high concentrations.
However, natural gas generators produce significantly lower levels of these pollutants compared to diesel generators. According to the U.S. Environmental Protection Agency (EPA), natural gas generators emit up to 50% less NOx and up to 90% less CO compared to diesel generators.
In addition to NOx and CO, natural gas generators also produce greenhouse gas emissions, mainly in the form of carbon dioxide (CO2). However, natural gas-fired generators are still considered to be a cleaner energy source compared to coal-fired generators, which produce higher levels of CO2 and other pollutants.
Safety and Durability
When it comes to converting a diesel generator to natural gas, safety and durability are two important factors to consider. While it is possible to convert a diesel generator to run on natural gas, it is important to ensure that the process is done safely and that the generator will remain reliable and durable in emergency situations.
One of the main safety concerns with converting a diesel generator to natural gas is the potential for explosions. Natural gas is highly explosive and can be dangerous if not handled properly. It is important to ensure that the conversion process is done by a professional who understands the risks involved and knows how to mitigate them.
In addition to safety concerns, durability is also an important factor to consider. Diesel generators are designed to be durable and reliable in emergency situations, and it is important to ensure that the generator will remain reliable after it has been converted to run on natural gas. Natural gas can be corrosive and can cause damage to the engine over time, so it is important to choose a conversion kit that is designed to withstand the corrosive effects of natural gas.
Maintenance After Conversion
After converting your diesel generator to natural gas, you will need to perform regular maintenance to ensure it continues to run efficiently and effectively.
One of the main benefits of converting to natural gas is that it is a cleaner fuel source, resulting in less pollution and fewer emissions. However, this does not mean that you can neglect maintenance. Regular cleaning of the generator is still necessary to prevent the build-up of dirt and debris, which can negatively impact performance.
In addition to cleaning, it is important to check the oil levels and change the oil as needed. Natural gas burns cleaner than diesel, which means that the oil will stay cleaner for longer, but it still needs to be changed periodically to ensure proper lubrication of the engine.
Another important aspect of maintenance is to regularly inspect the fuel lines and connections. Natural gas is delivered to the generator through a pipeline, and any leaks or damage to the connections can result in a loss of pressure and reduced performance.
Finally, it is important to follow the manufacturer’s recommended maintenance schedule for your specific generator model. This may include tasks such as replacing the air filter, checking the spark plugs, and conducting a load bank test.
By following these maintenance guidelines, you can ensure that your converted natural gas generator continues to run efficiently and cleanly for years to come.
Limitations and Considerations
Converting a diesel generator to run on natural gas is possible, but it is not without its limitations and considerations. Here are some factors you need to keep in mind before making the switch:
Efficiency
One of the biggest limitations of converting a generator to natural gas is efficiency. Natural gas is not as energy-dense as diesel, so generators may not be able to produce as much power when running on natural gas. However, newer and more efficient generators can overcome this problem.
Compatibility
Converting a generator to run on natural gas requires significant modifications to accommodate the differences in fuel properties. Fuel system modifications include installing a new fuel supply line, pressure regulator, and natural gas carburetor. Engine modifications may also be necessary to ensure compatibility.
Availability
Another consideration is the availability of natural gas. While natural gas is generally cheaper than diesel, it may not be as readily available in some areas. You will need to ensure that a reliable and consistent supply of natural gas is available before making the switch.
Cost
Converting a diesel generator to run on natural gas can be expensive, especially if you need to make significant modifications to the engine. You will need to weigh the cost of conversion against the potential savings in fuel costs.
Maintenance
Finally, it is important to keep in mind that natural gas generators require different maintenance than diesel generators. You will need to ensure that you have the necessary expertise and resources to maintain and repair your natural gas generator.
Industry Applications
If you are considering converting your diesel generator to natural gas, it is important to understand the various applications where natural gas engines are commonly used in the industry. Here are some of the most common applications:
Industrial
Industrial applications for natural gas engines include power generation, oil and gas production, and mining. Natural gas engines are popular in these industries because they are more environmentally friendly and cost-effective than diesel engines.
Rail
Natural gas engines are also used in locomotives and railcars. The rail industry has been transitioning from diesel to natural gas engines because they emit less pollution and are more cost-effective in the long run.
Marine
Marine vessels, such as ships and boats, can also benefit from natural gas engines. Natural gas engines are cleaner and quieter than diesel engines, making them ideal for use in marine environments. They are also more fuel-efficient, which can save money on fuel costs.
Trucks
Trucks are another industry where natural gas engines are becoming more popular. Natural gas engines are used in commercial trucks, such as garbage trucks and delivery trucks, because they emit fewer pollutants and are more cost-effective to operate.
Choosing the Right Conversion Kit
When it comes to converting your diesel generator to natural gas, the first step is to choose the right conversion kit. There are several conversion kits available in the market, and choosing the right one can be overwhelming. Here are a few things to consider when selecting the right conversion kit for your generator.
Type of Conversion Kit
The first thing to consider is the type of conversion kit. There are two main types of conversion kits: fuel adapter kits and bi-fuel kits. Fuel adapter kits are the easiest and least expensive conversion method. They require minimal labor and involve adding a few components to your generator. Bi-fuel kits, on the other hand, are more complex and expensive. They involve adding a separate fuel system that runs on natural gas alongside the existing diesel system.
Generator Size
The size of your generator is also an important factor to consider when choosing a conversion kit. Make sure to select a conversion kit that is compatible with the size of your generator. Using a conversion kit that is not compatible with your generator can lead to inefficiencies and other issues.
Efficiency
Another important factor to consider is efficiency. Natural gas is less energy-dense than diesel, so generators may not be able to produce as much power when running on natural gas. Make sure to choose a conversion kit that maintains the same level of efficiency as your diesel generator.
Cost
The cost of the conversion kit is also an important consideration. Fuel adapter kits are generally less expensive than bi-fuel kits. However, bi-fuel kits may be more cost-effective in the long run, as natural gas is typically less expensive than diesel.
Manufacturer
Finally, make sure to choose a conversion kit from a reputable manufacturer. Look for conversion kits that are certified by regulatory bodies such as the Environmental Protection Agency (EPA) and the California Air Resources Board (CARB).
By considering these factors, you can choose the right conversion kit for your diesel generator and ensure a smooth transition to natural gas.
Must Read: Does Kohler Make a Diesel Generator?
Dealing with Power Outages
Power outages can be frustrating and even dangerous, especially if they occur during extreme weather conditions. Having a backup generator that can run on natural gas can be a lifesaver during such situations. If you have a diesel generator, you may be wondering if it is possible to convert it to run on natural gas.
The good news is that it is possible to convert a diesel generator to run on natural gas. However, you will need to install an adapter between the gas supply and the carburetor. The adapter combines the natural gas vapors into the air stream above the carburetor. In most cases, you do not need to modify the generator’s carburetor.
When it comes to dealing with power outages, dual fuel generators are a great option. These generators can run on either gasoline or natural gas, which means that you can switch between the two fuels depending on availability and cost. Dual fuel generators are also more efficient than single fuel generators, which means that you can get more power for your money.
Portable generators are another option for dealing with power outages. These generators are designed to be moved around easily, which means that you can take them with you wherever you go. Portable generators can run on gasoline or natural gas, depending on the model. They are also available in different sizes, which means that you can choose the right size for your needs.
Understanding Remanufacturing
If you’re considering converting your diesel generator to natural gas, you may want to explore remanufacturing as an option. Remanufacturing is the process of restoring a used engine to like-new condition. In the case of converting a diesel generator to natural gas, remanufacturing involves removing the diesel engine and replacing it with a natural gas engine.
Remanufactured diesel generators are diesel generator sets that have had their engines completely redone to make it as close to new as possible. This process involves stripping out all internal parts and components of the engine and replacing them with parts and components that conform to OEM standards. The result is a generator that performs like new but with a natural gas engine.
One of the main benefits of remanufacturing is that it is a cost-effective way to convert your diesel generator to natural gas. Remanufactured engines are typically less expensive than new engines, making them a great option for those on a budget.
Another benefit of remanufacturing is that it is an environmentally friendly option. By repurposing a used diesel generator, you are reducing waste and minimizing your carbon footprint. Plus, natural gas engines produce fewer emissions than diesel engines, making them a cleaner alternative.
When choosing a remanufactured engine, it’s important to work with a reputable company that follows strict quality control standards. Look for a company that offers a warranty on their remanufactured engines and has a proven track record of success.
Frequently Asked Questions
Can a diesel generator be converted to run on natural gas?
Yes, it is possible to convert a diesel generator to run on natural gas. However, the conversion process can be complex and requires specialized knowledge and equipment. It is recommended to consult with a professional before attempting to convert your generator.
What is the cost of converting a diesel generator to natural gas?
The cost of converting a diesel generator to natural gas can vary depending on several factors, such as the size and age of the generator, the type of natural gas conversion kit used, and the cost of labor. On average, the cost can range from $1,500 to $5,000.
Is it possible to convert a diesel generator to run on propane?
Yes, it is possible to convert a diesel generator to run on propane. Propane is a popular alternative fuel for generators because it is readily available and burns cleaner than diesel fuel. However, the conversion process can be more expensive than converting to natural gas.
What are the benefits of converting a diesel generator to natural gas?
Converting a diesel generator to natural gas can provide several benefits, such as lower fuel costs, reduced emissions, and longer engine life. Natural gas is also a cleaner burning fuel than diesel, which can result in improved air quality and reduced environmental impact.
Are there any risks or drawbacks to converting a diesel generator to natural gas?
While there are several benefits to converting a diesel generator to natural gas, there are also some risks and drawbacks to consider. For example, natural gas is less energy-dense than diesel fuel, which means that generators may not be able to produce as much power when running on natural gas. Additionally, the conversion process can be expensive and may require significant modifications to the generator.
Are there any reputable companies that specialize in diesel to natural gas generator conversions?
Yes, there are several reputable companies that specialize in diesel to natural gas generator conversions. It is important to do your research and choose a company that has experience and expertise in this area. Some well-known companies include Cummins, Generac, and MTU Onsite Energy.
