Maximizing the Life – and Methane Emissions Reduction - of Legacy Cat® G3500 Engines

Cat® G3500 engines, recognized for reliability and robust performance, have powered gas compression sites for decades. As these durable power solutions approach overhaul maintenance intervals, operators have a new option to consider that not only promotes longevity but also reduces greenhouse gas (GHG) emissions.

G3500 LE Gen2 engine showing the overhaul
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The G3500 LE Gen 2 Kit is an upgrade that enables operators to continue to experience dependable performance for the operational life of the engine. When performed during an overhaul, the G3500 LE Gen 2 Kit is simple to install and cost effective. It features an updated cylinder head gasket and spacer as well as a cuffed cylinder liner, and, most importantly, maintains the engine’s maintenance intervals and performance.

Reduced Methane Emissions to Support Evolving Regulatory Requirements

The G3500 LE Gen 2 Kit not only helps operators optimize total cost of ownership (TCO) but also significantly reduces methane emissions up to 35% . Methane slip – unburned methane in the exhaust – is a common challenge with older gas engines and the G3500 LE Gen 2 Kit is the only available solution to decrease methane emissions up to 35% on the G3500 platform.

The G3500 LE Gen 2 Kit represents the most economical approach to reducing methane emissions with existing G3500 LE assets. By implementing the G3500 LE Gen 2 Kit, operators can proactively prepare for shifting emission standards. In geographic regions that enforce methane regulations or fees, such as Canada’s carbon pricing initiatives or Colorado’s state emissions rules, cutting methane emissions by one-third can reflect significant cost savings due to reduced regulatory fees.

Enhanced Operational Efficiency

Uptime and cost containment are critical in gas compression operations, and the G3500 LE Gen 2 Kit provides both. The kit immediately integrates into existing setups without requiring changes to site operations. This eliminates the need for extensive personnel re-training or modifications to compression facilities.

This is an important consideration as operators evaluate available options. Converting a gas compression site to operate on an electric motor, for example, demands significant infrastructure changes, new power supply configurations, and high upfront capital costs. Such a change can also introduce uncertainty with certain operating costs, such as electricity pricing.

In contrast, the price of overhauling the engine and installing the G3500 LE Gen 2 Kit is approximately half the cost of converting to an electric motor and avoids the complexities that come with a major equipment change. The kit provides a low-risk, cost-effective path to reduce methane emissions while optimizing operational efficiency. G3500 owners can minimize downtime, expenses and GHG emissions while maximizing compression throughput and reliability.

As gas compression operators seek to remain nimble as industry requirements evolve, the G3500 LE Gen 2 Kit delivers important advantages. It extends equipment longevity, maintains reliable performance, and significantly cuts methane emissions at a fraction of the cost of purchasing new equipment. Implementing the kit during a scheduled overhaul enables operators to experience these benefits with minimal disruption.

This technological advance empowers operators to balance operational efficiency and sustainability goals in a compelling way. Contact your local Cat dealer for assistance with scheduling an overhaul and upgrade.

1 At 1.5–2.0 g NOx setting with fuels containing methane. Reduction measured as exhaust-out emissions as compared to G3500 LE engine without kit. See Gas Engine Rating Pro (GERP) for site-specific data sheet for further details.

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