Retired jet engines find new life powering data centers amid energy crunch

Old Jet Engines Powering Data Centers: A Clever Solution to an Energy Crisis

The insatiable demand for computing power, especially with the explosive growth of AI, is placing unprecedented strain on global energy infrastructure. Data centers, the beating heart of our digital world, are ravenous consumers of electricity. As traditional power grids and new gas turbine installations struggle to keep pace, an ingenious and surprisingly effective solution is emerging from an unlikely source: retired jet engines.

The Growing Energy Chasm

Building massive data centers often goes hand-in-hand with constructing dedicated power plants or securing direct connections to the nearest electrical grid. However, the sheer speed at which demand for computational resources is escalating has created a significant supply bottleneck. Manufacturers of industrial gas turbines, like industry giants GE, Vernova, and Siemens Energy, are facing extended lead times. We're talking about waiting periods that stretch from three to five years, and in some cases, even longer. Paul Browning, CEO of Generative Power Solutions, starkly illustrates the issue, stating that there's simply a shortage of gas turbines, a problem that is only set to worsen. Industry analyses from Wood Mackenzie suggest that new gas turbine deliveries are scarce until well after 2029, and the Institute for Energy Economics and Financial Analysis (IEEFA) reports delays of up to eight years for new power station projects in regions like Southeast Asia. This alarming deficit has inadvertently paved the way for a burgeoning market focused on breathing new life into decommissioned aviation engines.

From Sky High to Ground Power

For decades, companies such as GE Vernova and Siemens Energy have been repurposing retired aircraft engines for stationary power generation. A prime example is the GE LM6000, a powerful unit derived from the CF6-80C2 jet engine, which once propelled commercial airliners through the skies. These repurposed turbines offer distinct advantages over their heavy-frame industrial counterparts: they are notably lighter, more compact, and significantly easier to maintain. It's a brilliant marriage of aerospace engineering and terrestrial power needs.

ProEnergy's Innovative Approach

At the Data Center World Power expo in San Antonio, the energy company ProEnergy showcased its impressive retrofitting process. They acquire, meticulously refurbish, and then integrate used CF6-80C2 gas generators, the core of the GE LM6000, into their own PE6000 branded gas turbine units. The result is a robust, reliable power source. Each of these revitalized units possesses the capability to generate a substantial 48 MW of electricity, a capacity perfectly suited for powering small to medium-sized data centers. Landon Tessmer, ProEnergy's VP of Commercial Operations, revealed that the company has already secured contracts for 21 of these turbines, destined for two data center projects with a combined capacity exceeding 1 GW. Astonishingly, ProEnergy can deliver these units as early as 2027, a stark contrast to the multi-year waiting lists from original equipment manufacturers.

Advantages and Future Impact

Beyond the speed of delivery, these refurbished turbines boast impressive operational efficiencies. They can be brought online within a mere 5 minutes and, in the unlikely event of maintenance, can be swapped out within 72 hours. Furthermore, their environmental impact is carefully managed, with emissions averaging a mere 2.5 parts per million of nitrogen oxides. Every engine undergoes a rigorous overhaul process; thousands of components are meticulously disassembled, cleaned, inspected, repaired, or replaced. This exhaustive procedure ensures that clients receive a unit that is essentially new, custom-built, and engineered for extended operational life. ProEnergy has been remarkably productive, manufacturing 75 PE6000 systems since 2020, with an additional 52 either in assembly or already on order. In a world grappling with a global turbine shortage, this second life for aviation engines as power generators could prove to be absolutely vital in sustaining the momentum of the AI revolution.