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DHKWs

DHKW plants and industrial energy systems.

Concept design, engineering and technical implementation of DHKW plants and energy-efficient system solutions for industrial applications.

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Compressed-Air Heat & Power Plants

Generating compressed air and heat with high efficiency.

A DHKW replaces electrically driven compressed-air generation with a directly driven screw compressor powered by a gas, biogas, or prospectively hydrogen-capable engine. The resulting waste heat is also put to productive use.

Basic Concept

A compact, turbocharged gas engine directly drives a screw compressor. This generates compressed air mechanically from natural gas or biogas rather than electrically – hydrogen is a future option.

Compressed air generated directly from mechanical engine power
Waste heat used from engine cooling, exhaust and compressed-air cooling
Reduces electrical peak loads and power costs

Typical Example

A compact, turbocharged natural gas engine built for maximum efficiency and power output (e.g. 2G Energy 406 natural gas, 248 kWmech) directly drives a screw compressor (e.g. Aerzener VMX). This generates, for example, 40 m³/min of compressed air at 8 bar(g). At the same time, usable heat is available for heating or process heat.

Direct drive instead of electrical compressor power
Example design: 40 m³/min of compressed air at 8 bar(g)
Payback period depends on operating hours and electricity and gas prices – we calculate it for your site
Energy Flow

How drive, compressor and heat use work together.

Using a typical design as an example, the following diagram shows how a single fuel input simultaneously produces compressed air and multiple stages of usable heat.

Energy flow diagram of a DHKW: gas engine directly drives a screw compressor, heat is recovered via the HT and LT circuits and an exhaust heat exchanger

Example energy flow overview: the gas engine mechanically drives the compressor to generate compressed air, while heat from engine cooling, compressor oil, exhaust gas and compressed-air cooling is recovered across several heat exchanger stages and supplied to the customer at a usable temperature level.

Want to reduce energy costs and CO₂ in your compressed-air generation?

Then generate compressed air with our DHKW from natural gas or biogas – and in future hydrogen – instead of electricity, and use the waste heat for heating or process heat as well.

Application Profile

Where does a DHKW work particularly well?

The economic benefit is greatest where compressed-air demand is high, operating hours are long, and there is a significant gap between electricity and gas prices.

Production from two shifts upward

Particularly attractive where compressed-air and heat demand is consistently or regularly high.

Favourable gas price

Advantageous for companies that are already large-scale natural gas consumers or can use alternative fuels.

High electricity price

With high operating hours, a DHKW can significantly reduce operating costs compared with electrical compressed-air generation.

Planned renewal

Ideal when replacing an old compressor or expanding an existing compressed-air station.

Why does a DHKW pay off?

Compressed air is one of the most expensive energy carriers in operation.

This is exactly where the DHKW comes in: electrical compressor output is reduced or replaced, while usable heat is generated at the same time. Several savings levers take effect simultaneously.

Less electricity for compressed air. More usable energy from the fuel input.

In conventional compressed-air generation, electrical energy powers the compressors and much of the resulting heat goes unused. A DHKW generates compressed air mechanically via a gas or biogas engine and also makes the waste heat usable.

↓ Reduced electrical compressor output
2× Compressed air and heat from one system
90°C Usable temperature level achievable
24/7 Especially strong with high operating hours

Conventional compressed-air station

High electricity demand from compressors
Heat is often only partially used
Electricity price spikes directly affect operating costs
Expansion often requires higher grid connection capacity

DHKW principle

Compressed air generated directly from mechanical engine power
Waste heat can be used for heating or process heat
Electricity consumption for compressed air can be significantly reduced
Ideal for high compressed-air and heat demand

1. Savings through electricity substitution

The biggest lever is reducing electrical compressor work. The higher the electricity price, operating hours and compressed-air demand, the stronger the economic case for a DHKW.

less electrical work for compressed air
lower power peaks possible
relief for electrical infrastructure

2. Added value through heat recovery

Heat from the engine, exhaust and compressed-air cooling can be put to use. This turns compressed-air generation into a combined energy system.

supports heating and process heat
better overall energy utilisation
high efficiency with matching heat demand

3. Economical with long operating hours

A DHKW is especially worthwhile for multi-shift operation, continuous base load, or planned expansions of compressed-air supply.

production with regular compressed-air demand
base-load operation especially attractive
replacing or supplementing existing compressors

4. Future-ready fuels

Besides natural gas, depending on the engine concept, biogas or, prospectively, hydrogen-capable solutions can also play a role.

natural gas and biogas – hydrogen as a future option
CO₂ reduction depending on fuel
compatible with future energy strategies

The key point: the DHKW must match the load profile.

We assess compressed-air demand, heat demand, operating hours, energy prices and installation conditions, and determine whether a DHKW makes technical and economic sense.

Check Savings Potential Send Data
References

Realised DHKW configurations – all in operation.

All configurations shown here are in operation at customer sites – depending on compressed-air demand, control behaviour and installation site, from fixed-speed units to containerised outdoor installation.

In operation

TGA240 DHKW

Configuration for high compressed-air output, e.g. 40 m³/min, with intake control.

In operation

TGA160 DHKW

Fixed-speed design for high efficiency and a robust base load.

In operation

VTGA160 DHKW

Variable delivery volume via speed control for more flexible load profiles.

In operation

Container-DHKW

Suitable for outdoor installation and modular integration on site.

Process

From analysis to operation.

For a DHKW, early technical assessment is decisive: compressed-air profile, heat profile, operating hours, fuel costs, installation site and integration with existing systems.

01

Analysis

Compressed-air demand, heat demand, run times, energy prices and existing infrastructure.

02

Concept

Engine, compressor, heat utilisation, controls, installation site and interfaces.

03

Implementation

Engineering, manufacturing, assembly, integration and commissioning.

04

Operation

Support, maintenance, optimisation and technical assistance during ongoing operation.

Example 3D installation layout of a DHKW in a plant room, with all relevant interfaces and connections marked

Example installation planning: this shows how a DHKW, including exhaust routing, silencer and connections, is technically integrated into the existing plant room – including all relevant interfaces marked for assembly and commissioning.

Certifications

Certified quality.

Our processes and services are audited by independent bodies – a reliable basis for your projects.

Quality management

ISO 9001:2015 – certified by TÜV Rheinland

Our quality management system is certified to ISO 9001:2015. Scope: design, development, assembly, commissioning, maintenance and operation of machinery.

Certificate no. 01 100 2100837 · valid from 01.10.2026 to 30.09.2029 · certificate in German
View ISO certificate
Water Resources Act

Specialist company under § 62 AwSV (WHG)

WB Engineering is certified by TÜV SÜD as a specialist company according to § 62 AwSV (WHG). This qualification supports legally compliant work on systems involving water-polluting substances and provides additional safety, quality and legal certainty for industrial, energy and plant engineering projects.

View WHG certificate

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