NETL-Led Research Team Exploring New Technology For Increased Power Line Capacity and Efficiency

A research team consisting of private sector and academic partners and led by NETL is working on a new ultra-conductive carbon aluminum composite cable technology that could increase the electrical conductivity and strength of transmission cables leading to higher grid capacity and efficiency to accommodate future power generation demand.

In addition to NETL, the research team includes, Ohio University, MetalKraft Technologies, Frisk Alloy, Hydro Extensions, General Graphene Corporation and CONSOL Innovations.

Known as ultra-conductive carbon aluminum composite (UCAC), the novel approach will have superior electrical and mechanical performance for use in power lines to transport electricity reliably and efficiently.

The nation's electrical grid faces significant challenges to meet the accelerated demand for electricity that is occurring because of increased building and transportation electrification. Conductors like aluminum and copper currently used in grid applications, allow substantial energy losses and have high costs, low durability and limited capacity to integrate renewable energy electricity sources.

Researchers said they believe UCAC cables can address critical issues by significantly increasing the electrical conductivity and strength which can lead to higher grid capacity, durability, and efficiency to handle future power generation and demand.

NETL's Congjun Wang explained that UCAC cables can upgrade existing and newly constructed power grids and offer performance, economic and environmental advantages.

"The performance of UCAC conductors will be enhanced by incorporating NETL's high-quality carbon materials - graphite and graphene - into aluminum using a novel hot-extrusion technique," he said.

He added that the UCAC cable technologies have the potential to increase electricity transport efficiency by more than 30%, enhance line capacity by more than 187%, lower CO₂ emissions by 10.3 million tonnes per year and enable seamless integration of diverse and intermittent energy sources.

"We believe this technology's durability and cost-effectiveness will reduce installation and maintenance costs, supporting a resilient nationwide energy distribution network," Wang said.

NETL is a U.S. Department of Energy national laboratory that drives innovation and delivers solutions for a clean and secure energy future. By leveraging its highly skilled innovators and state-of-the-art research facilities, NETL is advancing carbon management and resource sustainability technologies to enable environmental sustainability for all Americans.

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