RECD vs Dual Fuel Kit: Which Solution Does Your DG Set Need?

Looking for a DG set solution that provides cleaner operations and lower fuel dependence while you explore solutions to improve your generator’s performance? Two solutions frequently stand out in comparisons, like RECD vs Dual Fuel Kit. Both solutions serve different purposes and use different technology. So, before making any decision, you must understand which solution your DG set requires. If your purpose is to clean your DG set exhaust and reduce smoke and harmful pollutants. Then, you can go with a Retrofit Emission Control Device (RECD). On the other hand, when your goal is for your DG set to work with gaseous fuel and reduce diesel consumption, then a dual fuel kit may be your solution. 

Choosing one solution also depends on various factors for an existing DG set, such as engine type, capacity, functionality, fuel consumption, and practical uses. This blog provides a quick comparison between RECD and a dual fuel kit. We also help you to find a suitable solution for your DG set needs. 

What is an RECD for a DG Set?

RECD stands for retrofit emission control device. This is an emission control device that is designed to reduce harmful pollutants released through the exhaust. It is installed on the existing diesel generator (DG set) without replacing the old generator system. RECD is a cost-effective solution that helps reduce harmful matter from the generator such as particulate matter (PM), hydrocarbons (HC), carbon monoxide (CO) and nitrogen oxides (NOx). The process of an RECD involves exhaust gas treatment, whereby as exhaust gas flows through the system, the filtering or treatment system helps reduce any particulates and other types of emissions from the gas stream. In this way, exhaust gas emission control is achieved without altering the fueling system of the generator.

What is a Dual Fuel Kit for a DG Set?

A dual fuel kit is a system that allows a diesel generator (DG set) to operate using diesel along with a suitable gaseous fuel, such as natural gas, depending on the system design and engine compatibility. Instead of relying entirely on diesel, the kit introduces gas into the engine’s combustion process while retaining diesel as a fuel source. The system works by supplying a controlled amount of gaseous fuel to the engine along with diesel. The diesel continues to play an important role in the combustion process, while the gas can replace a portion of the diesel requirement under suitable operating conditions. This can help reduce diesel consumption and potentially lower operating costs. A dual fuel kit is particularly useful where a reliable supply of suitable gaseous fuel is available and the DG set is compatible with dual fuel operation.

RECD vs Dual Fuel Kit Quick Comparison 

RECD and dual fuel kits are both designed to support DG sets, but both have different functions, features, and capacities. The table below will help you to find key differences between RECD vs dual fuel kit.  

Comparison Factor	RECD	Dual Fuel Kit
Purpose	It is used for controlling smoke and reducing pollutants from the DG set exhaust.	It is generally used to reduce fuel consumption for diesel generators.
Primary Function	It involves exhaust after-treatment and emission control.	Fuel substitution through dual fuel operation.
Installation	Generally involves retrofitting the emission-control device into the exhaust system	Requires integration with the fuel system and appropriate gas-supply arrangements
Diesel Savings	This is not primarily designed to reduce diesel consumption.	It can reduce diesel consumption when it’s operated under suitable conditions
Maintenance	Requires inspection and maintenance of the emission-control equipment	Depends on engine type, DG specifications, gas compatibility, and dual-fuel system design
Fuel Requirement	Primarily continues to use diesel	Requires diesel plus a compatible gaseous fuel
Emission Control	Primarily targets exhaust pollutants such as particulate matter and smoke, depending on the system.	May help reduce certain emissions through reduced diesel use, depending on the fuel, engine, and operating conditions
Engine Compatibility	Depends on DG capacity, engine type, exhaust configuration, and system specifications	Depends on engine type, DG specifications, gas compatibility, and dual-fuel system design
Operating Considerations	Requires suitable exhaust conditions and proper operation of the emission-control system	Depends on gas availability, load profile, diesel-gas ratio, and engine operating conditions
Best Suited For	DG set users primarily focused on controlling exhaust emissions	DG set users primarily focused on reducing diesel consumption through gaseous-fuel substitution

Factors to Consider Before Choosing in RECD vs Dual Fuel Kit

Before choosing any advanced solution for your DG set, you must prioritize these common factors to get the right solution for your DG set. 

DG Set Capacity and Engine Type

This is one of the most important factors that you need to consider as your top priority. You need to check your DG set’s capacity, engine model, fuel system, and exhaust configuration. Not every RECD or dual fuel kit is compatible with every generator. Confirming compatibility can help prevent installation and performance issues.

Operating Load and Running Hours

You must know how much time your diesel generator (DG set) works and how long it takes time to load. You should know running hours, average load, peak load, and whether standby or continuous operation can influence the suitability and potential benefits of each solution.

Fuel Availability

For a dual fuel kit, you must have sufficient fuel availability because it requires multiple fuels. Check fuel availability, supply reliability, pressure requirements, storage or pipeline infrastructure, and associated operating requirements before choosing this option.

Purpose and Operating Goals

Finally, identify what you actually want to achieve. If your priority is emission control, an RECD may be the more suitable option. If your priority is reducing diesel consumption through gaseous-fuel substitution, a dual fuel kit may be more appropriate. The decision should be based on your DG set’s requirements rather than choosing one solution simply because it appears cheaper or better.

Common Mistakes to Avoid While Selecting a DG Set Retrofit Solution

Choosing a retrofit solution for your DG set can be easier when you know what to avoid while installing an RECD and a dual fuel kit. Here are some common mistakes that should be avoided before any installation of a DG set retrofit solution. 

Choosing Only by Price

Many buyers choose a retrofit solution simply because it has a low initial price, but they don’t consider other expenses. You should also count maintenance, fuel requirements, operating costs and service expenses while planning a retrofit solution. A slightly higher initial investment may provide better value over time, depending on your DG set and usage.

Treating Both as the Same

As we know, both retrofit solutions are designed to improve the DG set, but both have different functions that impact the DG set’s engine specifications. An RECD is mainly focused on controlling pollutants and reducing smoke, while, on the other hand, a dual fuel kit allows the DG set to use a suitable gaseous fuel along with diesel. Every buyer must know the difference between an RECD and a dual fuel kit.   

Not Checking DG Set Compatibility

Every RECD or dual fuel kit is not designed for every diesel generator. Before choosing a retrofit solution, check your DG capacity, engine, model, exhaust system and fuel setup. Ignoring these details can lead to installation problems, poor performance or an unsuitable system. Always confirm that the selected solution is compatible with your specific DG set. 

Ignoring Gas Availability

If you consider dual fuel for your DG set, then you must have a reliable supply of suitable gaseous fuel to work properly. Before choosing this solution, check whether the required gas is available at your site and whether you have the necessary supply infrastructure. Ignoring gas availability can make the system difficult to operate and may reduce its expected benefits.

Overlooking System Requirements

Every DG set retrofit solution has certain requirements for installation and operation. Before choosing an RECD or dual fuel kit, you must check the available space, exhaust setup, fuel supply, engine specifications, and supporting equipment. Ignoring these requirements can create installation problems or affect the system’s performance. Make sure your DG set can support the selected solution.

Skipping Technical Evaluation

Before any installation of an RECD or dual fuel kit, there is an important step that checks your DG set’s technical condition. You must do a DG Set assessment and look at some main factors such as engine type, DG capacity, load, exhaust system, fuel setup, and operating conditions. If you skip this step, it can lead to compatibility issues, poor performance, or unnecessary expenses.

When Should You Choose an RECD?

A retrofit emission control device (RECD)  may be a suitable choice when your main goal is to control emissions from an existing diesel DG set while continuing to use its primary fuel system. Here are additional factors to consider when choosing an RECD. 

• Emission Control: If you want to control smoke and particulate matter from your DG set exhaust, then an RECD will help you with this.
• Existing DG Set: When you want to improve the quality of a diesel generator without replacing it. Then this retrofit solution is good for you because its installation doesn’t require a new generator. 
• Exhaust Treatment: If you have a clear goal to clean your exhaust and reduce harmful gases such as Particulate matter, hydrocarbons, carbon monoxide, and nitrogen oxides.
• Diesel Operation: Whether you want to use continuous fuel, RECD is a good option for you. It focuses on emission control rather than replacing or changing the primary fuel system.
• Emission Requirements: If your DG set needs to meet applicable emission-control requirements, an appropriate RECD may be worth considering, depending on its specifications and suitability.
• Installation and Compliance Requirements: Before selecting an RECD or dual fuel kit, check whether the proposed system meets the applicable regulatory, emissions, safety, and installation requirements for your DG set and location.
• Total Cost of Ownership: Don’t compare systems only by their installation price. Consider equipment cost, installation, maintenance, fuel or gas costs, downtime, servicing, and expected operating benefits.

When Should You Choose a Dual Fuel Kit?

A dual fuel kit may be a suitable choice when your main goal is to reduce diesel consumption by using a suitable gaseous fuel alongside diesel. There are some more explanations to show when you should choose a dual fuel kit for your DG set. 

• Gas Availability: If you have a reliable supply of gas, then you can go with a dual fuel kit because the dual fuel system requires a suitable and consistent gaseous fuel supply for regular operation.
• Diesel Reduction: Whether you want your DG set to consume less diesel because dual fuel kit can allow gas to substitute for part of the diesel under suitable operating conditions.
• DG Compatibility: When you have a DG set which has compatibility to install dual fuel kit, then you can consider this solution because the system needs to match all these engine types, DG capacity, fuel system, and operating conditions.
• Fuel Cost: If you want to reduce your overall fuel expenses, then you can consider a dual fuel kit because using suitable gaseous fuel may help reduce your dependence on diesel and optimize fuel costs.
• Operating Profile: If your DG set runs regularly at suitable loads or good running hours, then you can consider a dual fuel kit because your running hours and load pattern can affect how effectively gas can substitute for diesel.

Frequently Asked Questions

If you are still confused about choosing between a retrofit solution and a dual fuel kit for a DG set. Here are some common questions that help you to understand more about these retrofit solutions. 

Conclusion 

When we do an RECD vs. dual fuel kit comparison to find a solution for a DG set is not possible because of its benefits or cost-effectiveness. Both systems are designed to improve the quality of diesel generators (DG sets). But they have different functions like RECD is mainly suitable for controlling pollutants from the DG set’s exhaust, whereas a dual fuel kit can help reduce diesel consumption by using a suitable gaseous fuel with diesel. The final decision for your DG set depends on several factors such as the DG set’s engine type, capacity, load, running hours, fuel availability, and system compatibility. A proper technical evaluation can help you determine which solution is right for your DG set.