Every previous Burke proposal started by trying to close the airport — the single hardest, slowest regulatory gate in Cleveland. This proposal does the opposite: the airport stays open and the main runway keeps flying. The energy campus is built entirely on the ±150-acre dredge-disposal peninsula on the northeast corner of Burke — the confined-disposal fill east of the East Basin that is already closed to the public and unusable for aviation. Vehicles reach it through a single secured gateway on the southeast side, and a continuous security wall, vegetated buffer, and patrol road separate the campus from the active airfield to the south, satisfying FAA Part 139 air-operations-area separation. The campus is anchored by a 500 MW hyperscale data center — expandable to 1 GW — powered by an on-site GE Vernova 7HA turbine power island with exhaust-heat steam recovery, and it still turns Lake Erie water into green hydrogen and green ammonia while layering civic space and a full educational pipeline on top.
The campus integrates seven converging pillars: a 500 MW hyperscale data center (reserved to grow to 1 GW) cooled by Lake Erie deep water; an on-site GE Vernova 7HA gas-turbine power island whose turbine exhaust is captured by heat-recovery steam generators to make steam for campus hot water and district heating, and which is engineered to co-fire the campus's own green hydrogen; a reserved, pre-permitted footprint for a small modular reactor (SMR) that lifts the campus to 1 GW of firm, zero-carbon baseload; Lake Erie water purification and PEM electrolysis producing green hydrogen; Sierra Energy FastOx gasification converting Cleveland MSW into syngas; Haber-Bosch green ammonia synthesis; and active discharge reoxygenation returning expelled water to full ecological health — all behind a hardened security wall that keeps the campus and the airfield completely separate. At full operation the campus supports 1,200+ permanent high-quality jobs and generates roughly $1.2B/year in gross revenue, anchored by the data center.
The campus occupies only the ±150-acre dredge-disposal peninsula on Burke's northeast corner — the confined-disposal fill east of the East Basin. The 6,604 ft primary runway and all active airfield land to the south are untouched and keep operating. Because the fill is engineered dredge material, every heavy structure sits on driven piles to bearing strata. A continuous 12-ft security wall, a 100-ft vegetated buffer, and a perimeter patrol road run along the entire southern boundary, separating the campus from the airfield's air-operations area per FAA Part 139; the only vehicular entry is a hardened secured gateway on the southeast side off N. Marginal Road. A reserved interior parcel is pre-graded for a small modular reactor. City retains fee ownership via 99-year ground lease.
Submerged intake crib 300–600 m offshore draws below the thermocline. Fish exclusion screens at <0.15 m/s protect aquatic life. Shoreline treatment train: softening (ion exchange) → reverse osmosis → deionisation polishing to <1 µS/cm conductivity. At 500 MW electrolyser input, water consumption is ~3.6M litres/day — trivial against Lake Erie's 25,700 km² surface. The intake station doubles as a Great Lakes Water Quality monitoring hub partnered with Cleveland Water Alliance and NOAA's Great Lakes Environmental Research Laboratory.
500 MW of proton exchange membrane electrolysis — 7.5 t H₂/hr, 180 t/day — housed in long, low pile-supported halls on the peninsula's western fill cells. Green hydrogen now serves four offtakes: co-firing the 7HA power island (displacing natural gas over time), Haber-Bosch ammonia feedstock, industrial H₂ sales at ~$4/kg (~$70M/year), and marine bunkering. O₂ byproduct (99.5% pure) sold to Cleveland Clinic at ~$8M/year. The IRA §45V clean hydrogen production tax credit of $3/kg for 10 years adds $47.5M/year, transforming project fundamentals.
FastOx shaft gasification — derived from Kaiser Steel blast furnace technology by Sierra Energy (Davis, CA) — converts Cleveland MSW at temperatures exceeding 2,200°C using oxygen and steam injection. No preprocessing required. Waste descends through drying, pyrolysis, gasification, and partial oxidation zones producing clean syngas (H₂ + CO) and inert vitrified slag suitable for road aggregate. The syngas feeds the Haber-Bosch ammonia synthesis loop after water-gas shift reaction and CO₂ removal. Cleveland pays gate fees to tip waste at the campus instead of landfill, converting a $15–20M/year cost center into a revenue stream. Zero liquid discharge design.
The campus's primary generation and the data center's dedicated power: GE Vernova 7HA-class gas turbines in 1×1 combined-cycle blocks delivering approximately 500 MW net. Turbine exhaust (≈630°C) is captured by heat-recovery steam generators (HRSGs); the steam drives a steam turbine for additional output and bleeds process steam for campus hot water and district heating — a true combined-heat-and-power island rather than simple-cycle waste. The 7HA is rated to co-fire hydrogen, so the campus's own green H₂ progressively displaces natural gas. A reserved, pre-graded interior parcel and switchyard headroom let a small modular reactor add firm zero-carbon baseload and lift the site to 1 GW. Backup and island resilience come from a fuel-flexible generation fleet — Mainspring Energy linear generators paired with Hyliion KARNO modules, plus BESS — sized N+1 so the campus rides through any grid or turbine event. Mainspring's units are shipping commercially today and anchor near-term availability; KARNO scales into the fleet as it reaches volume. Both run on natural gas now and the campus's green hydrogen as it ramps.
1,200 t/day green ammonia plant combining electrolytic H₂ with nitrogen from an on-site Air Separation Unit. Synthesis loop operates at 150–300 bar, 400–500°C over iron catalyst with K₂O and Al₂O₃ promoters. Only 15–25% converts per pass; unreacted gas recycles. Ammonia serves three simultaneous markets: zero-carbon fertilizer for Great Lakes agriculture, hydrogen carrier for marine bunkering (cracked back to H₂ at point of use), and pipeline export to the NE Ohio industrial corridor. The FastOx syngas-to-ammonia integration creates a circular economy: Cleveland MSW becomes fertilizer. Truck loading bay is the most safety-critical zone — IDLH 300 ppm NH₃, MC-331 tanker specifications, vapor recovery, emergency shutdown.
New point of common coupling (PCC) on the Shoreway corridor connecting to Cleveland Public Power and FirstEnergy. IEEE 1547-2018 islanding provision with anti-islanding protection, fault current limiting, and frequency response. The campus can disconnect from the grid and continue serving all loads autonomously during utility outages — a transformational resilience upgrade for Cleveland's lakefront, which currently goes dark in any grid disturbance. Qualifies for Ohio's capacity market. The LEEDCo Icebreaker Wind submarine cable lands here, making Burke the onshore hub for Lake Erie offshore wind.
Onshore landing for the LEEDCo Icebreaker Wind submarine cable — six turbines generating up to 126 MW approximately 13 km offshore from Burke. A dedicated submarine cable landing at this zone makes Burke the onshore hub for Lake Erie offshore wind. The electrolyser farm directly absorbs curtailed offshore generation that would otherwise be wasted. During periods of high wind and low demand, excess electricity drives electrolysis rather than being curtailed — effectively converting storage-less wind into storable hydrogen. This is the "long game" for scaling the campus to full 500 MW electrolyser capacity.
The completed dredge-disposal cells are the campus itself; the bunkering pier is built along the peninsula's north bulkhead on Lake Erie, coordinated with the US Army Corps and Port of Cleveland. A hydrogen and liquid-ammonia bunkering facility here makes Cleveland the first Great Lakes port to offer green hydrogen marine fuel. The International Maritime Organization's 2050 decarbonisation targets are driving rapid adoption of alternative fuels across the Great Lakes fleet. IMO-compliant H₂-grade fueling station; NH₃ cracking-on-demand for ships preferring H₂ combustion. Serves bulk carriers, container vessels, and passenger ferries to Canada.
High-pressure H₂ tube storage at 350 bar plus cryogenic liquid ammonia tanks. Buffer capacity of 72 hours at full production rate. Functions as a grid-scale virtual battery: during low-demand periods surplus production fills storage; during peaks, stored H₂ raises the 7HA hydrogen co-fire fraction and can drive additional export. This demand-response capability qualifies for ancillary-services payments from PJM. The storage field also decouples the electrolyser schedule from the power island — absorbing electrolyser output during low-load periods and buffering H₂ supply to the turbines during transients.
The anchor tenant and economic engine: a 500 MW IT-load hyperscale campus phased 100 → 250 → 500 MW, with a reserved, pre-permitted footprint and power headroom to reach 1 GW. Powered directly by the on-site 7HA power island (SMR-ready), it needs no scarce grid capacity — the constraint that stalls hyperscale siting everywhere else. Lake Erie deep-water cooling achieves sub-1.1 PUE: raw intake → traveling screens → RO filtration → heat-exchanger battery → CRAH + direct-liquid-cooling manifolds → warm return → reoxygenation cascade → UV → submerged diffuser. DLC for AI GPU clusters at up to 130 kW/rack; diverse fiber to the Cleveland One carrier hotel. Leased wholesale to a hyperscaler, it is developer-/tenant-financed off the city's balance sheet.
The public amenities zone faces Lake Erie along the northern edge. The key addition beyond previous Burke proposals is an Energy Discovery Centre — a world-class science attraction making the campus's water-to-energy systems visible. Visitors walk above the electrolyser farm on a glass-floored observation deck, watching hydrogen being produced from Lake Erie water. Great Lakes Science Center partnership natural — it sits immediately adjacent on North Coast Harbor. Campus buildings draw on the 7HA power island (rising green-H₂ co-fire), CHP district heat, and solar canopies over parking and public gathering areas. This is where the campus earns its public legitimacy — and finally opens 2 miles of lakefront that 85% of Clevelanders currently cannot access.
Case Western Reserve University — 5 km east on Euclid Avenue, with 80 years of electrochemistry leadership and six Electrochemical Society fellows — co-operates a Clean Energy Research Institute with Cleveland Clinic. CWRU's Great Lakes Energy Institute researches batteries, fuel cells, PEM membrane development, and electrochemical engineering; the Burke campus gives them what no university lab can replicate: a full-scale operating PEM electrolyser farm. A PhD student investigating new PEM membrane materials installs test cells directly into the Burke electrolyser farm and collects real performance data under real fouling, pressure cycling, and water quality variation — conditions a university lab can only approximate. Cleveland State's Midwest Hydrogen Center of Excellence also anchors here.
A submerged intake crib positioned 300–600 metres offshore draws water below the thermal stratification layer — consistently 38–55°F year-round regardless of surface ice or summer warming. Fish exclusion screens at mesh 1 mm, approach velocity controlled to under 0.15 m/s, meet Great Lakes Water Quality Agreement (GLWQA) requirements non-negotiably. Raw intake capacity: 40,000 gallons per minute feeding the shoreline pump station. At 500 MW electrolyser load, water consumption is approximately 3.6 million litres per day — a trivial draw on a lake with 25,700 km² of surface area.
The treatment train achieves electrolysis-grade feedwater in three stages: (1) Softening via ion exchange removes calcium, magnesium, and other hardness ions that would foul PEM membranes; (2) Reverse osmosis reduces TDS by 95%+ and removes particulates; (3) Final deionisation (DI) polishing achieves <1 µS/cm conductivity — the specification required by PEM electrolyser manufacturers to protect the proton exchange membrane and avoid accelerated stack degradation. This ultra-pure water is what makes the electrolyser farm's claimed 80,000-hour stack life achievable.
500 MW of PEM electrolyser current passes through the purified water: 2H₂O → 2H₂ + O₂. The proton exchange membrane allows only protons (H⁺) to pass, producing high-purity hydrogen at the cathode. At 50 kWh/kg system efficiency, 500 MW produces approximately 10,000 kg of hydrogen per hour — 180 tonnes per day. PEM output H₂ is approximately 99.9% pure, at 30–50 bar, containing trace moisture. Stack lifetime at rated current density: approximately 80,000 hours (about 9 years) before major stack replacement, a primary O&M cost driver.
PEM output hydrogen contains trace moisture and <0.1% oxygen. A pressure swing adsorption (PSA) drier or membrane drier reduces dewpoint below −40°C, protecting high-pressure storage vessels from internal corrosion. A catalytic deoxo unit (palladium catalyst) removes O₂ to <1 ppm where required by storage specifications. For direct turbine co-fire supply, the deoxo step is often omitted. Final purity: 99.95%+ H₂, dry, at 30–50 bar — ready for buffer storage, the 7HA fuel skid, or compression to 350 bar for tube storage and transport.
A hydrogen buffer decouples the electrolyser schedule from turbine demand: it absorbs electrolyser output during low-load periods and steadies H₂ supply to the 7HA co-fire skid during transients, while the Mainspring + KARNO backup fleet covers black-start and momentary island events. The 72-hour bulk storage field (Zone 9) provides the strategic buffer for grid services, demand response, and raising the turbines' hydrogen co-fire fraction on demand.
The GE Vernova 7HA turbines generate the campus's electricity, burning natural gas at commissioning and progressively co-firing the green hydrogen produced upstream. Rather than vent the ≈630°C exhaust, heat-recovery steam generators capture it to raise steam — driving a bottoming steam turbine for extra megawatts and bleeding process steam for campus hot water and district heating. That combined-heat-and-power recovery is what lifts overall fuel efficiency well past a simple-cycle plant. Every added kilogram of on-site H₂ co-fire lowers the carbon intensity of the whole campus, and the reserved SMR parcel offers a firm zero-carbon path to 1 GW.
The power island is a dedicated ≈500 MW GE Vernova 7HA combined-cycle CHP plant that powers the data center directly — sidestepping the grid-capacity queues that stall hyperscale siting everywhere else. Exhaust heat becomes steam for power and district heat; the turbines are built to co-fire the campus's own green hydrogen; and a reserved SMR parcel gives a firm zero-carbon route to 1 GW. A fuel-flexible backup fleet — Mainspring linear generators + Hyliion KARNO, plus BESS — provides N+1 backup, black-start, and full island capability.
The Haber-Bosch synthesis loop — combining electrolytic hydrogen from Lake Erie water with nitrogen from atmospheric air — produces 1,200 tonnes of zero-carbon ammonia per day. Simultaneously, the FastOx gasifier converts Cleveland's municipal solid waste into syngas that supplements the hydrogen feedstock, creating a genuine circular economy.
| Process Stage | Input | Output | Key Parameter |
|---|---|---|---|
| FastOx Gasification | Cleveland MSW (unprocessed) | Syngas (H₂ + CO + CO₂) | 2,200°C · O₂ + steam injection |
| Water-Gas Shift | Syngas + steam | H₂-rich gas + CO₂ | CO + H₂O → CO₂ + H₂ |
| CO₂ Removal | Shifted syngas | High-purity H₂ | Amine scrubbing or pressure swing |
| Air Separation Unit | Atmospheric air | Pure N₂ (78% of air) | Cryogenic distillation |
| Gas Mixing | H₂ + N₂ | Synthesis gas | 3:1 H₂:N₂ ratio |
| Haber-Bosch Loop | Synthesis gas | NH₃ (15–25% per pass) | 150–300 bar · 400–500°C · Fe catalyst |
| Ammonia Separation | NH₃ + unreacted gas | Liquid NH₃ · recycled gas | Cooling + condensation |
| Storage & Loading | Liquid NH₃ | Tank storage / tanker loading | −33°C / 1 atm · or 10–17 bar pressurized |
The AI and cloud industry faces a global power-and-cooling crisis: hyperscalers cannot find sites that offer both large firm power and viable cooling. Burke's NE campus solves both at 500 MW, with a clear runway to 1 GW. The on-site 7HA power island (SMR-ready) supplies dedicated power without waiting in a grid-interconnection queue; Lake Erie deep water removes mechanical-chiller dependency and holds PUE below 1.1.
The Burke campus creates a five-tier educational pipeline connecting every level of Cleveland's academic ecosystem to real careers in clean energy — and uniquely, every tier uses the Burke campus itself as a live classroom. No simulation. No approximation. Real industrial hydrogen infrastructure at real operating scale.
Field trips from Cleveland Metropolitan School District (CMSD) elementary schools to the Energy Discovery Centre — the glass-floored observation deck above the electrolyser farm. Students in grades 3–6 watch hydrogen being made from lake water in real time, then trace it into the 7HA power island, where it is co-fired to make the electricity powering the lights in the building they're standing in. Curriculum modules co-developed with CMSD science teachers aligned to Ohio science standards.
MC² STEM High School, John Hay STEM, and Early College High School are natural feeders. The campus creates two distinct pathways:
Technician Pathway: Junior technician apprenticeships for 10th–12th graders — 10–15 paid hours per week on-site. Students rotate through water treatment operations, electrolyser monitoring, turbine, Mainspring/KARNO genset, and BESS module checks, and control-room data logging. These are entry-level positions with union-negotiated wage scale, structured mentorship from licensed plant operators, and a guaranteed Tri-C interview upon graduation. Burke becomes one of the SWAG program's anchor employers.
Engineering Pathway: AP Chemistry, Physics, and Environmental Science co-taught by CMSD teachers and CWRU faculty using Burke plant data as primary source material. A student's AP Chemistry lab assignment might be analysing the purity of hydrogen output from the electrolyser. Dual enrolment via Ohio's College Credit Plus earns Tri-C credit for courses taken on or near Burke.
Tri-C's Workforce Innovation division — Metropolitan Campus 3 km from Burke — partners with the campus to create entirely new Ohio credentials that don't currently exist. The Burke campus creates demand for workers with skills no Ohio college currently certifies:
Electrolyser Technician Certificate: 30-credit, one-year programme combining electrochemistry fundamentals, PEM stack maintenance, water treatment operations, H₂ handling and confined space safety certification, and 200 hours of supervised plant hours at Burke. First programme of its kind in the Great Lakes region. Career starting salary: $55,000–$70,000. Journeyman wages above $80,000 after five years.
CSU's Energy Policy Center operates the Midwest Hydrogen Center of Excellence — covering hydrogen economy, microgrids, energy storage, electricity markets, and district energy systems. The Burke campus is the infrastructure that validates everything the RHFCC (Renewable Hydrogen Fuel Cell Collaborative, operating out of CSU) has been advocating for. CSU gains a live demonstration facility 15 minutes from its main campus.
Fenn College of Engineering BS students rotate through paid co-op placements at Burke — semester-long rotations counting toward degree requirements. Senior capstone projects tackle live engineering challenges: optimising electrolyser farm dispatch schedules, modelling district heating network thermal losses, designing protection relay settings for the microgrid islanding system.
CWRU's Great Lakes Energy Institute was built on 80 years of electrochemistry leadership — 15 faculty members spanning 5 departments, six Electrochemical Society fellows, researching batteries, fuel cells, PEM membrane development, and electrochemical engineering. CWRU broke ground in October 2024 on a $300 million Interdisciplinary Science and Engineering Building collocating 60+ principal investigators from engineering, medicine, and sciences working on climate change, sustainable manufacturing, and materials science.
The Burke campus gives CWRU what no university lab can replicate: a full-scale, operating PEM electrolyser farm producing tens of tonnes of hydrogen per day. A PhD student investigating new PEM membrane materials installs test cells directly into the Burke electrolyser farm and collects real performance data under real operating conditions — fouling, pressure cycling, water quality variation — conditions a university lab can only approximate. The DOE awarded CWRU $10.75 million to establish a Breakthrough Electrolytes for Energy Storage research centre.
| System / Zone | CapEx Estimate | Phase | Notes |
|---|---|---|---|
| Zone 1 — Water intake & treatment | $120M | Phase 1 | Intake crib, RO, DI polishing, treatment train |
| Zone 2 — PEM electrolyser farm (500 MW) | $600M | Phase 1 | $700–900/kW declining benchmark; 2029 pricing |
| Zone 3 — FastOx gasification | $380M | Phase 2 | Sierra Energy; 200+ t/day MSW throughput |
| Zone 4 — GE Vernova 7HA power island (≈500 MW) | $650M | Phase 1 | 1×1 combined cycle; HRSG CHP; H₂ co-fire; SMR-ready |
| Zone 5 — Haber-Bosch ammonia (1,200 t/day) | $550M | Phase 2 | ASU + synthesis loop + storage |
| Zone 6 — Grid interconnection & substation | $95M | Phase 1 | 345kV; IEEE 1547; Icebreaker tie-in |
| Zone 7 — LEEDCo offshore wind tie-in | $45M | Phase 2 | Onshore landing + transformer yard |
| Zone 8 — Marine H₂ bunkering pier | $280M | Phase 4 | IMO-grade; Army Corps bulkhead; cryo NH₃ |
| Zone 9 — H₂ & NH₃ storage field | $310M | Phase 2 | 350 bar tubes; cryo tanks; 72-hr buffer |
| Zone 10 — Data center (500 MW, 1 GW-ready) | $5.5B | Phase 1–3 | ~1.5M sq ft; lake cooling; DLC; tenant-financed |
| Zone 11 — Public lakefront campus | $180M | Phase 3 | Energy Discovery Centre; hotel; promenade |
| Zone 12 — Research & education campus | $220M | Phase 3 | CWRU/CSU/Cleveland Clinic institute; labs |
| Site civil — piles, cap, security wall, SE gateway | $150M | Phase 1 | Dredge-cell cap; deep piles; wall + buffer; no airfield work |
| SMR reserve parcel (future 1 GW upgrade) | Future | Phase 4+ | Pre-graded; NRC track; separately financed |
| Owner's costs, soft costs & contingency (15%) | ~$530M | All | Architecture, permitting, project management |
| TOTAL PROJECT CAPEX | ~$9B | 2029–2035 | Fully-loaded with 500 MW DC + 7HA; ~$1.1B energy core |
| Metric | Value | Scenario |
|---|---|---|
| Simple payback (productive assets, ex-DC) | ~6.8 years | Base case, $4/kg H₂ |
| Simple payback with IRA §45V credit | ~3.8 years | $4/kg + $3/kg PTC = $7/kg effective |
| Project IRR (20-year model, ex-DC) | 8.5–10.5% | Range reflects H₂ price & ramp timing |
| Unlevered NPV @ 7% discount rate | ~$180–240M | After full federal grant netting |
| DSCR (stabilized 2034) | 1.70× | Above 1.35× lender covenant minimum |
| DSCR with §45V credit | 3.51× | Dramatically de-risks debt service |
| EBITDA margin (stabilized, ex-DC) | ~28% | ~$44.5M/yr on $157.5M/yr revenue |
| City annual land lease income | $5M/yr | Perpetual; city retains fee interest |
| City annual PILOT revenue | ~$8–12M/yr | Payments-in-lieu-of-taxes on improvements |
| Annual debt service (DOE + bonds) | $26.2M/yr | $13.8M DOE + $12.4M revenue bonds |
| Net cash flow after debt service (stabilized) | ~$18.3M/yr | Growing ~2.5%/yr with revenue |
Every previous Burke proposal asked Congress and the FAA to close the airport — the slowest, least certain approval in the entire project. This plan removes that ask entirely. By building only on the closed NE dredge-disposal peninsula and keeping the main runway and Part 139 operations intact, the campus sidesteps the closure fight while still qualifying for the same federal clean-energy programs — now joined by data-center/AI and advanced-nuclear (SMR) pathways.