The explosive growth of artificial intelligence (AI) and data centers is reshaping the energy landscape, demanding unprecedented levels of power that traditional grids and supply chains are struggling to meet. With AI workloads requiring massive computational resources, data centers are projected to see their power demand double or even triple by 2028, potentially reaching between 325 to 580 terawatt-hours per year in the U.S. alone.
This surge is exacerbating a critical shortage of new gas turbines, with wait times for large-scale units stretching into 2030 due to manufacturing bottlenecks and overwhelming orders tied to AI expansion.
In response, innovative solutions are emerging, including the repurposing of retired military and commercial aircraft engines into high-efficiency power generators. This approach not only taps into existing resources but also provides a rapid, deployable fix to bridge the energy gap.
The Power Crunch: AI’s Insatiable Appetite
Data centers, the backbone of AI training and inference, are power-hungry beasts. By 2035, U.S. AI data centers could consume up to 123 gigawatts (GW), a more than thirtyfold increase from current levels.
Traditional natural gas plants, powered by gas turbines, are a go-to solution for reliable, on-demand energy. However, the global scramble for these turbines has created a bottleneck: Siemens Energy reports over 60% of its U.S. gas turbine orders are now linked to AI data centers, and GE Vernova anticipates an 80 GW backlog by the end of 2025.
The shortage is particularly acute for large turbines used in combined-cycle systems, leading to delays that can span years.
As a result, operators are turning to alternatives like onsite gas generators for prime power, bypassing grid connection hurdles.
Enter the unlikely hero: retired aircraft engines. These high-performance turbines, originally designed for aviation, can be modified into aeroderivative gas turbines that run on natural gas or distillate fuel oil. This repurposing offers a quick-win strategy, with units that can be bolted onto trailers and deployed in months rather than years.
Repurposing Retired Engines: A High-Flying Solution
The U.S. Energy Information Administration (EIA) recently highlighted the vast potential in the U.S. Air Force’s “Boneyard” at Davis-Monthan Air Force Base in Arizona, where over 4,000 retired military aircraft sit idle. Theoretically, their engines could generate up to 40,000 MW of electricity—equivalent to more than 10% of Arizona’s current generation capacity of 36,535.8 MW.
The breakdown includes about 32,000 MW from turbofan engines, 7,300 MW from turboprops, and 1,600 MW from turboshafts (e.g., T700 engines from MH-60 Seahawk helicopters, each rated at 1.2 MW).
While turbojets are inefficient and excluded, turbofans and similar types mirror the design of natural gas-fired combustion turbines, making them ideal candidates.
In practice, companies are already converting both military and commercial retired engines. ProEnergy, a Missouri-based firm, specializes in overhauling CF6-80C2 engine cores—used in aircraft like the Boeing 747-400, 767, MD-11, Airbus A300, and A310—into 48 MW PE6000 natural gas turbines.
These units convert thrust into shaft power, adding generators and controls for seamless integration. ProEnergy has sold 21 such turbines to two separate data center projects, delivering over 1 GW of new power.
Each engine provides 48 MW, enough to power a mid-sized data center cluster.
Boom Supersonic, known for its aviation ambitions, has entered the fray with its “Superpower” 42 MW natural gas turbine, adapted from aircraft engine technology.
Announced alongside a $300 million funding round, this unit targets AI data centers, with Crusoe Energy—a provider of AI cloud infrastructure—as its launch customer.
GE Vernova and GE Aerospace also play a role, with their LM6000 turbine based on the CF6 turbofan engine, offering aftermarket refurbishments.
These companies provide a bridge between the aviation and energy sectors.
Publicly Traded Players and Data Center Applications
Among the key innovators:ProEnergy: A private company focused on energy solutions, not publicly traded. It’s leading the charge with deployments in Texas data centers, where facilities have already integrated these 48 MW jet-engine generators.
Boom Supersonic: Also private, but backed by significant venture funding. Its Superpower turbines are set for Crusoe’s data centers, which support AI workloads for clients in energy-intensive regions.
GE Vernova (NYSE: GEV): Publicly traded since its spin-off from GE in 2024. It offers similar aeroderivative turbines and refurbishment services, positioning it to capitalize on the trend.
GE Aerospace (part of GE, NYSE: GE): Publicly traded through its parent company, with expertise in the CF6 engines that form the basis for many repurposed units.
Specific data centers include unnamed Texas facilities using ProEnergy’s tech and Crusoe’s operations, which leverage modular, onsite power to avoid grid delays.
These are often trailer-mounted for flexibility, providing temporary or permanent power amid the AI boom.
Filling the Turbine Shortage Gap
Repurposed aircraft engines address the gas turbine shortage by offering a faster, more accessible alternative. New turbines face lead times of 2-5 years due to supply chain constraints and surging demand from data centers.
In contrast, retired engines can be sourced, refurbished, and deployed in as little as 6-12 months, at potentially lower upfront costs—though challenges like engine condition (many retired over a decade ago), removal logistics, and conversion expenses remain.
This innovation not only recycles valuable assets but also supports the thermal energy revival, where natural gas remains a key feedstock for AI’s power needs.
As AI continues to drive economic growth, solutions like these could prevent energy bottlenecks from stalling progress, turning yesterday’s flight power into tomorrow’s digital fuel.
For more insights on energy trends, tune into the Energy News Beat Channel. As the demand for natural gas increases, this is something we will be monitoring.
Source: eia.gov, boomsupersonic.com
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