800 V DC at the generator
Isolation and AC-to-DC conversion happen inside the generator. No transformers, switchgear or separate rectifiers between the turbine and the racks.
The problem
The biggest constraint for AI data centres is timely power
11.8 %
Demand is outrunning the grid
US data centres could use 11.8 % of the country's electricity by 2030 (range 9.5–15.3 %).
2029–2030
New turbines and transformers are years away
New gas-turbine slots are largely committed to 2029–2030, and transformers take 2.5–4 years at current lead times.
18,500 A
Megawatt racks need DC
A 1 MW rack draws 18,500 A at 54 V but 1,250 A at 800 V DC. The latest GPU and CPU architectures are moving to 800 V DC.
The solution
800 V DC, available at the generator
A conventional turbine plant makes AC and reaches 800 V DC through transformers, switchgear and separate rectification. In CROSSOVER the generator converts 600 V AC to 800 V DC itself and feeds the racks on the shortest possible DC buses.
Conventional turbine plantAC output, then separate rectification
- Gas turbine
- 13.8 kV generator
- MV transformers, switchgear, breakers
- LV transformers, switchgear, breakers
- Separate rectification
- 800 V DC at the racks
No longer required with CROSSOVER
- MV and LV transformers
- Switchgear and breakers
- Separate rack rectifiers
- Turbine gearbox
Hyper Tech CROSSOVER800 V DC available at the generator
- Aero-engine gas turbine
- Generator with integrated rectification, 600 V AC to 800 V DC
- Multiple isolated 800 V DC (or ±400 V DC) buses of 2–5 MWEach bus isolated inside the generator, with local fuses and IGBT controls
- 800 V DC at the racks
Why CROSSOVER
What makes it different
Power years sooner
Built from existing aero engines, outside the queue for new turbines and the transformer backlog. First unit and pilot targeted for Q2 2028.
Lower cost at the racks
About $1,590 per kW against about $2,450 to reach 800 V DC conventionally: about 35 % less equipment cost, and about $83 per MWh against $100 for an AC turbine with DC conversion (modelled).
A fault stays on its bus
Multiple isolated buses of 2–5 MW, each with local fuses and IGBT controls. Fewer components, no gearbox, a smaller footprint.
The numbers
Cost of electricity, on one basis for every option
CROSSOVER burns the same natural gas as any simple-cycle turbine, about $43–45 per MWh at 37–39 % efficiency. It costs less at the racks because an AC plant also pays for transformers, switchgear and rectifiers, and loses 3–5 % in them.
Equipment cost to reach 800 V DC
A conventional 25 MW plant needs about $2,450 per kW of equipment to deliver 800 V DC: the turbine-generator, then transformers, switchgear and breakers, then AC-to-DC conversion. CROSSOVER is about $1,590 per kW, because the conversion chain is inside the generator.
~$860 per kW saved, about $0.86B per GW (modelled)
Cost of electricity at the racks
Hyper Tech CROSSOVER800 V DC direct
Hyper Tech CROSSOVER: $83 per MWh (Natural gas $45, Generator capital $26, O&M $12).
The referenceFirst unit Q2 2028 (target)
Simple-cycle turbineAC + DC conversion
Simple-cycle turbine: $100 per MWh (Natural gas $45, Generator capital $28, DC conversion $15, O&M $12).
+$17 per MWhSlots largely committed to 2029–2030
Natural-gas combustion enginesReciprocating, e.g. Cummins; AC + DC conversion
Natural-gas combustion engines: $97 per MWh (Natural gas $38, Generator capital $32, DC conversion $15, O&M $12).
+$14 per MWhTypically 12–18 months for large orders
Combined cycleAC + DC conversion
Combined cycle: $82 per MWh (Natural gas $30, Generator capital $31, DC conversion $15, O&M $6).
−$1 per MWh4–6 years to build, 100 MW+
Show the figures as a table
| Option, $ per MWh at the racks (800 V DC) | Natural gas | Generator capital | DC conversion | O&M | Total | Availability |
|---|---|---|---|---|---|---|
| Hyper Tech CROSSOVER, 800 V DC direct | 45 | 26 | – | 12 | 83 | First unit Q2 2028 (target) |
| Simple-cycle turbine, AC + DC conversion | 45 | 28 | 15 | 12 | 100 | Slots largely committed to 2029–2030 |
| Natural-gas combustion engines (reciprocating), AC + DC conversion | 38 | 32 | 15 | 12 | 97 | Typically 12–18 months for large orders |
| Combined cycle, AC + DC conversion | 30 | 31 | 15 | 6 | 82 | 4–6 years to build, 100 MW+ |
Modelled. One basis for every row: natural gas at $4.40/MMBtu (HHV), 85 % load factor, 15 years at a 9 % cost of capital. AC plants add $850/kW of transformers, switchgear and rectifiers and lose 4 % on the way to 800 V DC. CROSSOVER: 37.1 % efficiency (16 MW), $1,590/kW. Simple-cycle turbine: 38.5 %, $1,600/kW, same maintenance allowance. Natural-gas combustion engines: EIA heat rate and O&M, $1,850/kW. Combined cycle: Lazard LCOE+ 2026 midpoints. Diesel sets burn about $400 of fuel per MWh at $6 a gallon, so they are for backup. Estimates, not quotes.
Want this model run for your site? Request the NDA
What it looks like
From the generator to the GPU hall
The generators sit on the engine shaft and rectify on the machine. The DC leaves the skid on a short connection to the GPU modules. Select a picture to enlarge it.
The business opportunity
A large market priced on time to power
Data centres need tens of gigawatts of on-site power this decade, the racks are moving to 800 V DC, and the engines to build from are retiring every year.
Estimate
~$100B
Addressable equipment market
A ~40 GW on-site power gap for data centres, 2026–30, at ~$2,450/kW for conventional plant to reach 800 V DC.
≈ 19,000
CFM56 engines in service worldwide, the most-built jet engine family.
380 → 760
Engines a year expected to retire, as retirements rise from about 2 % to 3–4 % of the fleet between 2026 and 2027.
800 V DC
The latest GPU and CPU architectures are moving to 800 V DC. CROSSOVER is designed to deliver it from the generator.
Next
The same 800 V DC buses can later take fuel cells from Global Research & Development, Hyper Tech's companion company. What comes next
Investing in power for AI? Request the investor NDA
Programme and milestones
From load demonstration to volume production
CROSSOVER is a development programme. Design and manufacturing are in the United States, close to the customer. Dates are design targets.
Done
Multi-phase machine and converter
Isolated multi-phase windings in one machine; MVA-class conversion to DC.
2027
Load demonstration
The generator package tested under load.
Q2 2028
First unit and pilot
First-of-a-kind unit at a data-centre pilot site.
2029
Volume production
16 MW units, with a pathway to 20 MW.
Planning capacity for 2028 and beyond? Talk to us about the pilot
What comes next
The same 800 V DC buses, fed by fuel cells next
Global Research & Development Inc., Hyper Tech's companion company, is developing nano-membrane solid oxide fuel cells that produce DC directly and are packaged as 800 V DC units of 1 MW and up. A campus built on Hyper Tech's isolated DC buses can add or switch to them without rebuilding its power distribution.
Scale-up path: from single tube cells to a multi-tube module, then a stack on Hyper Tech's 800 V DC test stand (2027) and a 1 MW unit on one bus at the data-centre pilot (2028).
Fuel cells are already bought at data-centre scale: Oracle has agreed up to 2.8 GW of solid oxide fuel cells from Bloom Energy, with 1.2 GW firm (April 2026).
Now
Converted turbines
Natural-gas turbine-generator packages for behind-the-meter power: 16 MW per unit, with a pathway to 20 MW.
60 %
Fuel-cell efficiency target
Electrical efficiency target. The cells are multi-fuel: hydrogen, methane or natural gas, propane, and JP-8. At $4.40 gas that is a fuel cost of about $28/MWh, against about $43–45 for the turbine.
30–50 %
Lower capital cost target
Than present-day fuel cells, with a $2,000/kW target at scale. The electrolyte stack is under 800 nm thick. The same platform offers options for PFAS removal and on-site oxygen production.
Fuel-cell figures are Global Research & Development targets, not test results. Fuel cost computed here from the 60 % target at $4.40/MMBtu (HHV), assuming 98 % DC/DC to the bus. Liquid fuels such as JP-8 need sulfur removal and pre-reforming ahead of the stack. Oracle–Bloom figures as reported by enkiai.com (April 2026).
Brochure
The CROSSOVER brochure
The four-page brochure covers the two power chains, where the equipment cost goes, how CROSSOVER compares with other on-site options, and the cost of electricity at the racks. Select a page to read it.
Who it is for
Is CROSSOVER for you?
The public pages show the concept. The design data, the site economics and the financial model are shared under a mutual NDA.
Hyperscalers and data-centre developers
You need firm power on site, at 800 V DC, before the grid can deliver it
- 16 MW units, pathway to 20 MW, on multiple isolated 800 V DC buses
- No transformers, switchgear or separate rectifiers between the turbine and the racks
- First unit and data-centre pilot targeted for Q2 2028
Under NDA: generator design and test data, site interface and footprint, the cost-of-electricity model run for your site, and the pilot programme.
Request the NDA as a data centreInvestors
Hyper Tech is raising a Series A to put a first unit under load
- A behind-the-meter market priced on time to power
- About 35 % less equipment cost to reach 800 V DC (modelled)
- Built from existing aero engines, designed and made in the United States
Under NDA: the investor document, financial model, use of proceeds, terms, and the data room with the cycle model and generator design.
Request the NDA as an investorEngine supplier, manufacturer or EPC partner? Request the NDA as a partner.
- 1Request Tell us who you are and what you need.
- 2Sign We send a mutual NDA.
- 3Brief A briefing with Hyper Tech, then the data room.
Next step
Request the NDA
Tell us who you are. We send a mutual NDA, then arrange a briefing and access to the data room.
- Data centres: design and test data, site interface, cost model for your site, pilot programme
- Investors: investor document, financial model, terms and data room
Or contact Michael Tomsic, President, directly
mtomsic@hypertechresearch.com +1 740-517-3569Hyper Tech Research, Inc., 539 Industrial Mile Rd., Columbus, Ohio