Bi Fuel System Components

Bi-Fuel System  Components

Bi-fuel or dual fuel is a power generation system capable of simultaneously running on two different types of fuel, typically diesel and natural gas. Bi-fuel technology entails adding a natural gas fuel system to a diesel generator, allowing it to run on diesel and natural gas.

The bi-fuel system allows natural gas into the engine’s air intake system, where it’s mixed with the intake air. This mixture enters the combustion chamber, is combined with diesel fuel and ignited. Innovative control technology allows precise control over the amount of gas allowed into the engine to ensure maximum combustion efficiency while preventing engine damage.

Supplementing diesel with natural gas in a bi-fuel system offers various advantages, including lower fuel costs, improved emissions performance, and increased engine efficiency.

Bi-fuel System

A bi-fuel system comprises various components to help a diesel engine switch seamlessly between the two fuel types. Bi-fuel system components include:

Bi-Fuel Gases

A bi-fuel system can run with various gaseous fuels, including methane, wellhead, propane, CNG, LNG, or hydrogen. The choice of gas boils down to availability and affordability.

Gas Train

Dual fuel systems use a custom gas train comprising a mesh filter, manual ball valve, zero-pressure regulator, and an electric shutoff solenoid. The gas train uses an infinitely adjustable throttle valve to feed the mixer. The innovative gas train delivers precision control while providing exceptional safety measures.

Air / Gas Mixer and Fuel Control Valve

Bi-fuel systems use proprietary air-gas mixer and fuel control valves to deliver natural gas to the combustion chamber through the air intake system. The mixer is installed below the stock air filter for precise air-to-gas ratio control alongside the fuel control valve. The mixer draws the gas into the engine using the Venturi effect. The fuel control valve allows lightning-fast throttle adjustment to cope with varying engine load.

Control Module

A bi-fuel system uses a sophisticated computer control system to monitor and control the fuel blending process in real-time. It comprises advanced sensors and software algorithms that monitor fuel quality and adjusts the blend ratios as needed.

It communicates with other components, such as storage tanks and fuel dispensers, to create custom fuel blends that meet specific performance and emission standards.


Existing generators can easily be retrofitted with a bi-fuel system to deliver incredible costs saving benefits.


Bi-fuel systems are compatible with many diesel generators by leading brands, including Caterpillar, MTU, Kohler, John Deere, Cummins, Generac, Mitsubishi, and more.


The installation process does not require internal engine modification or changing the OEM fuel system controllers. No specialized tools are required for the installation, which is best handled by certified professionals. Certified engineers can install and commission the system and ensure seamless integration while minimizing downtime.


OptiBlend® is an innovative bi-fuel retrofit system that incorporates all the previously mentioned components into a safe, proven kit to convert new and existing diesel generators to bi-fuel. OptiBlend® uses specialized hardware kits and computer technology to help companies lower their diesel fuel consumption, extend runtime, and cut operating and maintenance costs.

Cost Savings

Bi-fuel systems running OptiBlend® technology can deliver as much as 50% savings on the cost of diesel. However, the actual cost savings depend directly on the cost of natural gas and diesel, run time, and the generator’s manufacturer and model.

Extended Runtime

The OptiBlend® kit works with new and existing engines and can potentially double the diesel engine’s run time.

Getting Started

While installing a bi-fuel system offers numerous costs saving benefits, the results may vary. Calculating the benefits is the only reliable way to determine if a company can benefit by installing a dual-fuel system. Working with a certified OptiBlend® engineer can guarantee accurate and dependable results.

Contact the OptiBlend® engineering team today!

  • Bi Fuel Gas Train Bi Fuel Gas Train - OptiBlend dual fuel gas train is a series of components to ensure filtered, quality gaseous fuel is fed at zero pressure into diesel engines through the air intake displacing 50%-70% of diesel fuel consumption.
  • Dual Fuel Air Gas Mixer Valve Bi Fuel Air Gas Mixer Valve (AGM) - OptiBlend dual fuel conversion uses an air gas mixer (AGM) to introduce gaseous fuel from the gas train into the air intake on diesel engines.
  • dual fuel control valve Bi-Fuel Control Valve - OptiBlend dual fuel conversion kits includes a fuel control valve fitted between the gas train and air gas mixer to control the flow of gaseous fuels into the diesel engine.

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*calculation assumes 70% displacement, 1 Gallon CNG = 5.66lbs , Diesel Equivelant = 6.384 lbs
**calculations are based on your input data and are approximations