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Omnitek develops diesel-to-natural gas engine conversion kits for Mercedes OM904/OM906
19 April 2012
|Diesel to natural gas conversion system. Click to enlarge.|
Omnitek has developed a kit that can be used to convert the globally popular Mercedes diesel engines OM904 and OM906 into natural gas engines.
Omnitek’s proprietary diesel-to-natural gas engine conversion kit is used for bus and truck applications, as well as stationary applications. It simplifies the engine conversion process by integrating the ignition control and electronic fuel injection into one control unit. The system offers closed-loop fuel control for low emissions, as well as J1939 CANbus communications with electronic gauges in the dashboard.
The Omnitek Kit includes all components needed to convert the diesel engine into a natural gas engine, such as low compression pistons, natural gas fuel injectors and ignition components, as well as an advanced electronic control module and multiple sensors. For applications requiring extra-low emissions, such as EURO IV or EURO V, Omnitek can also supply catalytic converters.
The conversion steps entail:
- Disassembling original engine.
- Checking components and replacing as necessary.
- Modifying pistons for gas use (lower compression ratio).
- Modifying cylinder head for spark plugs.
- Installing camshaft sensor and timing wheel.
- Reassembling engine.
- Installing throttle body, ignition system, gas mixer or fuel injectors.
- Tuning of the engine (fuel and ignition).
|Conversion in progress. Click to enlarge.||Finished conversion. Click to enlarge.|
For engines without turbocharger, the conversion cost is $7,000 - $10,000, including Omnitek Kit, Engine Modifications, and Labor. Gas tanks, engine overhaul parts and installation are extra. For engines with turbochargers, the conversion cost runs to $8,000 - $12,000. A Team of 5 - 7 technicians can convert 5 - 7 vehicles in one week.
Truck and bus operators have been particularly hard hit by the increase in the price of diesel, to a point, where converting to natural gas is many times the only way to stay in business. Converting to natural gas will not only reduce fuel costs, but also air pollution. It was particularly important to us to develop a system that is affordable and offers a rate of return around one year, and I think we have succeeded.—Omnitek CEO Werner Funk
|Piston modified for natural gas. Source: Omnitek. Click to enlarge.|
A converted bus with an OM904 engine has been operating in Mexico since January 2012. The lower priced natural gas is saving the bus operator 40% in fuel costs. The reduction in particulate emissions by more than 90% and lower greenhouse gas emissions (CO2) by 30% are further benefits offered by diesel-to-natural gas engine conversions.
The project in Mexico is managed by NatGas S de RL de CV, the Omnitek representative in the territory.
Earlier this month, Omnitek entered into a definitive agreement with investors for a private placement of common stock and warrants to raise approximately $5.0 million in gross proceeds. The funding is targeted to accelerate the build-out of a national network of diesel-to-natural-gas conversion facilities.
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