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  • What is Our Fuel Catalyst Solution?

Ours is a small cartridge that goes in your diesel fuel line and helps the fuel burn more completely. On-highway trucks typically use 3% to 5% less fuel. Mining equipment, locomotives, ships and generators typically use 5% to 7% less. CO2 drops by the same amount.

No magnets, no additives, nothing to refill. It's not magic, just chemistry and physics. Our catalyst is the Rentar Fuel Catalyst, made in the USA. Zelkam is an authorized Rentar distributor, and from Peoria, Illinois, we help fleets around the world size it, install it, test it and run the numbers.

Where it goes

  1. Fuel tank
  2. Fuel filter
  3. Our catalystInstalls here, in about 30 minutes
  4. Fuel pump
  5. Injectors
  6. Cylinders

Fuel flows from the filter through the catalyst and on to the fuel pump. We put it as close to the engine as we can.

How it works

Diesel is mostly long, straight-chain hydrocarbon molecules. As fuel flows over the rare-earth and other metals inside the cartridge, some of those long chains get "cracked" into shorter ones, and some get turned into ring compounds that give off a little free hydrogen. Oil refineries run these same two reactions, cracking and dehydrogenation, every day.

Shorter molecules mix with air and burn more easily, and hydrogen burns fast and hot. You get a quicker, more complete burn, so more of the fuel's energy pushes the piston and less goes out the stack as soot and smoke. A catalyst helps a reaction along without being part of it, so nothing gets used up and nothing ends up in your fuel or oil. If you want the full chemistry, see How It Works and Catalysis.

The short version

What it is
An in-line pre-combustion fuel catalyst. Not a liquid additive, not a magnet. Nothing gets added to the fuel.
Fuel savings
3% to 5% for on-highway trucks. 5% to 7% for mining, rail, marine, generators and other heavy equipment.
CO2
Drops by the same percentage as fuel, because all the carbon in CO2 comes from the fuel.
Payback
Typically 3 to 12 months, from fuel savings alone.
Installation
About 30 minutes. Any good mechanic can do it.
Maintenance
None. The catalyst isn't used up. The oldest units are over 20 years old and still working.
Engine sizes
About 75 HP to over 4,000 HP. Diesel, renewable diesel, biodiesel and fuel oil.
Warranty
3 years, plus the manufacturer's $1 million insurance policy.
Made in
The USA, using patented catalyst technology (33 patents). Zelkam handles sizing, installation, testing and support.

A few real results

  1. 7.3%
    Rogers Group, USA

    Fleet average across hundreds of units on all their large mobile equipment. They're the largest privately owned crushed-stone producer in the U.S.

  2. 4.4%
    C.R. England, USA

    10 trucks with our catalyst against 32 control trucks over 12.7 million miles. C.R. England ran the test and collected the data themselves.

  3. 10.8%
    Borusan, Türkiye

    Average on three port stackers, with a 3 to 6 month payback. Borusan wrote about the project in its 2023 sustainability report.

  4. 3.9%
    TasRail, Australia

    Average on three Cat 3512 locomotives over five months, checked two ways (engine data and emissions testing). They're now equipping the whole fleet.

  5. 3.1–5.2%
    Norbulk Shipping, UK

    On generators aboard three ships, measured with flow meters. Then they equipped their client's entire fleet.

  6. 7.4%
    Standards Institution of Israel

    Up to 7.4% less fuel in a 2023 government lab test, with no loss of engine performance.

Those are six of more than 100. See every test result, by industry, with who ran it and how.

I was a skeptic too

Brian Livingston, President of Zelkam

I'm a chemical engineer with 40+ years in industry, including almost 20 in Caterpillar's Diesel Engine Division. I don't claim to be the sharpest pencil in the cup, but I do know a bit about diesel engines and chemistry. When I first ran across this technology, I didn't believe it.

So I flew to Florida, toured the factory, and talked with the inventor, the people running the company and their customers. I read stacks of test reports and worked through the chemistry myself. That's what convinced me, and it's why I started Zelkam. If you're skeptical, good. I'd rather show you the data than ask you to take my word for it.

Brian Livingston, President, Zelkam LLC. More about me

Frequently asked questions

How is this different from the gas-saving gadgets the EPA has warned people about?

Fair question. I asked it myself. Most of those gadgets were sold to car owners with big promises and no data. We claim 3% to 7%, not 20% or more, and we back it with fleets that measured their own fuel over months and millions of miles, often against control vehicles. Independent labs like Southwest Research Institute, SGS and Millbrook have tested it too. And we'd rather you prove it on your own equipment before you buy a fleet's worth.

How much fuel will I really save?

On-highway trucks usually see 3% to 5%. Mining equipment, locomotives, ships, generators and other heavy diesel equipment usually see 5% to 7%. It depends on the engine, the duty cycle and the fuel. When we quote ranges, we throw out the very high results so we don't look ridiculous.

Will it void my engine warranty?

No. The Magnuson-Moss Warranty Act says a manufacturer can't void your warranty just because you used an aftermarket part. We also have letters from Caterpillar, Cummins, Mack and Volvo Trucks saying that installing a product like this doesn't, by itself, void their warranty. If an aftermarket part itself causes a failure, the engine maker won't cover that, which is why the manufacturer carries its own insurance.

What if it damages my engine?

The manufacturer carries a $1 million per-incident international insurance policy for engine or vehicle damage caused by the catalyst. It has been in force for over 20 years, with more than 28,000 units in the field, and nobody has ever filed a claim.

Is your catalyst legal to use in California?

Yes. Our catalyst is the Rentar Fuel Catalyst, and it's legal on the on-road heavy-duty diesel vehicles its exemption covers. CARB Executive Order D-394-14 (August 25, 2021) exempts the Rentar Fuel Catalyst from California Vehicle Code Section 27156. In it, CARB found that the catalyst does not reduce the effectiveness of any required motor vehicle pollution control system. CARB requires us to include this disclaimer, word for word: The Executive Order or the exemption it provides is not an endorsement or approval of any emission reduction or fuel economy claims for the Rentar Fuel Catalyst and is only a finding that the device is exempt from the prohibitions of Vehicle Code Section 27156.

What does the U.S. EPA say?

The EPA doesn't certify or endorse fuel catalysts. Its 2020 Tampering Policy says EPA will typically find a reasonable basis for installing an aftermarket part that CARB has exempted, under the same terms and limits as the CARB exemption. Our catalyst has that CARB exemption.

Does it work on engines with DPF and SCR aftertreatment?

Yes. The catalyst works on the fuel before it burns, so it doesn't touch your aftertreatment. It has been tested on DPF- and SCR-equipped engines internationally, including Tier 4 engines. Less soot coming out of the cylinder also means less soot for the DPF to deal with.

Does it work at idle?

Yes. It treats the fuel whenever fuel is flowing. An AAR-recognized lab measured 7% less fuel at idle on a locomotive engine.

Does it work with renewable diesel, biodiesel or heavy fuel oil?

Yes. A nationwide U.S. quarry company ran a one-year test on seven trucks and excavators at a California quarry running on renewable diesel (HVO) and measured 7.8% less fuel. Norbulk Shipping measured 3% to 5% on ship generators burning IFO 380 fuel oil. With biodiesel, it can also help offset biodiesel's higher NOx.

How do I test it on my own fleet?

Measure your baseline fuel use, install the catalyst (about 30 minutes), run normally through a 250-hour conditioning period, then measure again the same way. For an answer you can trust, test at least five machines against five similar control machines. Testing just one is a bit like flipping a coin. I'm happy to help you set it up, and the testing page has the details.

Are there other fuel catalysts?

A few other in-line catalysts and lots of liquid additives are out there. What sets ours apart is the evidence: more than 100 documented results across mining, trucking, rail, marine, generators and boilers. Fleets like Rogers Group, Del Monte, Norbulk Shipping, Borusan and TasRail tested it and then equipped their whole fleets.

Should we talk further?

If your fleet burns a lot of diesel, I'd be glad to run the numbers for your equipment and show you what 3% to 7% looks like in dollars and payback. No pressure. Let me know…

Schedule A Conversation

Or email Info@Zelkam.com, or call +1 847-893-9845.