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AI energy consumption strains power grid as data center demand drives costs up for manufacturers

Reviewed byNidhi Govil

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Data centers powering AI are consuming electricity at unprecedented rates, with global consumption hitting 565 TWh in 2026. US manufacturers in the Rust Belt are paying significantly higher electricity costs as data center demand strains the aging power grid. Some factories report energy bills jumping from $1,600 to $12,000 monthly, while steel companies face tens of millions in additional annual costs.

AI Energy Consumption Reaches Critical Levels as Grid Struggles

AI energy consumption is accelerating at a pace that threatens to overwhelm existing infrastructure, with global data center electricity consumption projected to reach 565 terawatt-hours (TWh) in 2026, up 26% from 447 TWh in 2025, according to Gartner forecasts

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. The surge in AI data center electricity demand is creating a cascade of consequences across the energy sector, from soaring energy costs for traditional industries to mounting pressure on utilities to build new generation capacity. By 2030, data center electricity consumption is expected to exceed 1,200 TWh, with AI-optimized servers accounting for nearly half of all data center power usage

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Source: Tom's Hardware

Source: Tom's Hardware

The strain on the aging energy grid has become particularly acute in regions served by PJM Interconnection, the largest power grid operator in the United States covering 13 states. PJM's capacity prices have skyrocketed from $28.92 per megawatt-day in 2024 to $329.17 per megawatt-day in 2026, reflecting the intense competition for limited power resources

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. The grid operator forecasts that electricity demand will surpass available supply by 6.6 gigawatts starting in 2027, equivalent to more than six nuclear power plants

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US Manufacturers Bear the Brunt of AI Boom Energy Demands

US manufacturers concentrated in Rust Belt states are experiencing the most immediate impact of rising data center demand. The Belden Brick Company, a 141-year-old Ohio manufacturer, has seen its monthly electricity bills surge from $1,600 to $12,000 due to higher capacity charges

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. For steelmakers, the situation is even more severe. The Steel Manufacturers Association warns that US steel companies are paying tens of millions of dollars in higher power costs annually, with electricity accounting for 20 to 40 percent of total production costs

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Source: Ars Technica

Source: Ars Technica

Ohio-based steelmaker Metallus reported a 70 percent jump in electricity costs since 2024, translating to an extra $15 million in annual energy expenses

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. The irony is stark: while data center construction requires an estimated 1 million tons of steel per year, the energy demands of those same facilities are undermining the economic viability of steel production itself. Some manufacturers are raising prices to offset costs or considering relocation, while steel executives warn that production outages could become more likely if local power grids are overwhelmed

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AI Servers Power Consumption Set to Overtake Conventional Infrastructure

The composition of data center energy use is shifting dramatically as AI servers power consumption accelerates. AI-optimized servers consumed approximately 95 TWh worldwide in 2025 and are projected to draw 175 TWh in 2026, representing an 84% increase

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. By 2027, AI-optimized hardware will consume more electricity than conventional servers for the first time, with AI servers expected to reach 258 TWh while conventional servers remain relatively flat at around 200 TWh

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In the United States, which accounts for approximately 204 TWh of the 565 TWh global total in 2026, dedicated AI data centers consume roughly 68 TWh, or one-third of the national data center electricity consumption

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. Gartner analyst Linglan Wang noted that "power availability is now the binding constraint on AI expansion," making data center power security "the new battle ground for scaling and protecting margins in the global AI race"

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Natural Gas Plants Surge as Clean Energy Goals Collide with AI Reality

The AI build-out has triggered the largest-ever construction boom in natural gas-fired power plants, according to the Associated Press, accomplishing what the fossil-fuel industry could not achieve on its own

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. Aging coal plants are being kept operational past planned retirement dates as utilities struggle to meet the immediate power needs of data centers. The arithmetic is straightforward but challenging: some data centers consume more electricity than a mid-size city, and renewable energy infrastructure cannot be built at the required speed

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Source: TechRadar

Source: TechRadar

This reality has sparked a regulatory battle as clean energy advocates push back. Several states including New York, Michigan, Oregon, and Minnesota have passed or are considering legislation requiring large data centers to meet renewable energy benchmarks, with targets reaching 90% clean energy by 2040

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. Michigan tied compliance to financial incentives, requiring hyperscale data centers to reach 90% clean energy within six years to maintain a lucrative sales tax exemption

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However, Bob Jenks of the Oregon Citizens' Utility Board offered a candid assessment: the 2040 climate goals target was already difficult to meet with data centers, and difficult to meet without them

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. More than 75 data center projects worth $130 billion were blocked in the first months of 2026 amid opposition over power and water costs, with some operators turning to on-site gas generators to bring capacity online without waiting for grid reliability improvements

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Competing Solutions Emerge for Powering the AI Boom

Experts and industry leaders are pursuing diverse strategies for powering the AI boom. Enhanced geothermal systems offer one promising path, providing baseload, carbon-free energy with 24/7 reliability that wind and solar cannot match without massive battery storage

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. Hyperscalers are making substantial commitments to nuclear power, with Meta signing deals for more than 6GW of nuclear capacity to supply upcoming data centers, though these projects won't come online until 2028 or later

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Regulatory changes are creating new pathways for tech companies to build their own generation. Google's deal with NV Energy, connecting 115 megawatts of geothermal systems in Nevada and 1,900 megawatts of wind, solar, and storage in Minnesota, is seen as the first of its kind, with similar arrangements approved or pending in eight more states

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. The pitch to utilities is commercial: they gain long-term customers who pay to expand the power grid rather than building standalone generation.

The International Energy Agency finds that the energy sector should be AI's natural home, generating more operational data than almost any industry

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. Yet the sector is struggling with weak digital skills and limited data interoperability, with information locked in proprietary silos. India's Ministry of Power launched the India Energy Stack in 2025, a digital public infrastructure modeled on the country's identity and payments systems, while the European Commission published its Strategic Roadmap for Digitalisation and AI in the Energy Sector in June 2026

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. These initiatives recognize that sustainable energy systems require not just new generation capacity but fundamental changes in how energy data is shared and managed.

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