Could Bimetallic 'Supermetals' Provide a
Solution?
by Craig York, Copperweld CEO
BRENTWOOD, Tenn., June 25,
2024 /PRNewswire/ -- The copper industry is driven by
a complex system of supply-and-demand cycles. One cycle of
particular concern, given the growing interest in decarbonization
technologies, involves the relationship between global copper
supply and green initiative copper demand. This co-dependency
presents a zero-sum scenario where copper supply deficits threaten
green initiatives, and green initiatives intensify the copper
supply crisis. To avoid a stalemate, the future of green programs
may depend on solutions that offer a more efficient and sustainable
use of copper.
Copper Supply Shortfall
Copper prices recently reached record highs, crossing the
$5/lb threshold for the first
time.1 Analysts attribute much of this price explosion
to soaring copper demand, mainly due to the large role copper plays
in renewable energy, decarbonization efforts, and power grid
investments.2
Over time, if increased copper demand is continually met with
reduced supply, shortfalls are soon to follow. In 2022, copper
production was about 22 million metric tons (MMT), while demand was
about 26 MMT; recycled copper scrambled to make up the
difference.2 Some analysts estimate the growing
supply-demand gap will result in an annual copper supply shortfall
of 8 million tons by 2034 — an outcome that would pose a
significant hurdle for the future of green energy
projects.3
How Does the Copper Shortage Threaten Green Goals?
It is estimated that the technology used in green initiatives
could eliminate 2/3 of global greenhouse gas emissions by 2050.
However, meeting net-zero carbon emission targets would require
doubling annual copper demand to 50 MMT. With copper suppliers
already struggling to increase output, that's unlikely to
happen.3
Richard
Adkerson, former CEO of U.S. mining group, Freeport-McMoRan,
predicts that surging copper demand will cause a supply shortfall
as society rapidly adopts electric cars, renewable electricity, and
power grid expansions.4
Wire and cable products are of particular interest in the usage
of copper for green programs. Overall, wire and cable use related
to the green energy transition could grow from 0.8 million MMT to
6.7 MMT between 2020 and 2040.3
While copper demand in conventional applications will increase
only 0.5% by 2040, there will be significant increases in copper
usage in some green energy sectors. This includes an 11% increase
in demand from electric vehicles (EVs) and chargers, a 19% increase
from grid expansion, and a 7% increase from renewable energy
technologies during this time frame.3
As our society moves forward with green energy initiatives, we
must conserve and reallocate copper resources. The solution is
found in copper supply management through copper-alternative
products in high-usage markets.
'Supermetals' — Bimetallic Wire Conserves Copper and Offers
Enhanced Performance
A bimetallic wire is an engineered electrical conductor that is
composed of two separate metals metallurgically bonded together,
combining the distinct characteristics of the two metals into one
'Supermetal'.
Copper is limited in its engineering options. To increase
strength, you must use more copper. With a bimetallic wire, an
engineered core of steel or aluminum can be used to provide
benefits like increased strength or improved energy efficiency
while conserving copper at the same time.
Unlike alloys which are a blend of metals throughout,
bimetallic wire often consists of a corrosion-resistant periphery
of copper with an inner core of metal chosen for its specific
performance characteristics. This construction opens a wide range
of engineering possibilities for leveraging the core of the wire to
create an electrical conductor that goes beyond copper's
capabilities alone.
Two popular bimetallic 'Supermetals' have forged a significant
presence in the power grid and construction markets:
- Copper-Clad Steel (CCS) grounding, power, and signal
conductors have been used in substations, power distribution,
underground utilities, mining, and transportation applications for
nearly a century.
- Copper-Clad Aluminum (CCA) is a bimetallic conductor
that has been widely used in telecommunication, data, and building
construction applications for over 50 years.
Bimetallic 'Supermetal' Benefits:
- Reduced Copper Consumption – Bimetallic conductors
optimize the use of valuable copper, in some cases using only 1/6
the copper found in solid copper wire.
- Improved Energy Efficiency – CCA building wire has
2.7% lower impedance, translating into energy savings and less
strain on the power grid.5
- Enhanced Strength – CCS conductors provide up to
three times more tensile strength than solid copper, allowing CCS
wires to be used in power grid and utility applications where
demanding conditions often lead to broken wire or loose connections
that can cause power outages and safety
hazards.6
- Extended Service Life – CCS conductors have up to
five times more flex-fatigue endurance, allowing wires to withstand
the bending, jerking, and vibration experienced in applications
that encounter repeated stress and impact.7
- Improved Connections – CCS wire's
corrosion-resistant copper exterior and annealed steel core allow
utility workers to 'bite down' on grounding wires, making solid
connections that remain secure through decades of abuse.
- Reduced Incentives for Theft – As the price of
copper reaches all-time highs, copper theft is an increasing issue.
Bimetallic wires have conveniently low street value, making them
less attractive to copper thieves.
- Improved Cost Stability – With lower copper
content, bimetallic wires reduce exposure to volatile price
fluctuations experienced with solid copper wires.
Of bimetallic wire's many advantages, two benefits represent the
potential for significant impact on decarbonization and green
initiative efforts:
1) Bimetals Conserve Copper
Focusing on industries that use large amounts of copper is key
to copper conservation efforts.
As the largest consumer of copper resources, the construction
industry accounts for almost half (45%) of the nation's copper
supply. And, within the construction industry, building wire alone
uses 20% of the total U.S. copper supply.8
Fortunately, the building construction industry already has an
alternative to single-metal copper wire: Copper-Clad Aluminum
(CCA). CCA building wire uses 1/6 the amount of copper when upsized
two AWG sizes compared to copper
conductors, as is required by the National Electric Code (NEC) for
most electrical circuits. This upsizing allows CCA to provide
comparable electrical performance to equivalently rated copper
conductors.
Utilizing CCA instead of single-metal copper for building wire
applications could have potentially saved the U.S. nearly 700
million pounds of copper in 2022! That's equivalent to the copper
required for 3.8 million EVs, enough solar farm capacity to
power 13.3 million homes (77,000 MW), or 175 wind
farms (approximately 175,00 wind turbines with 1.5-MW
capacity). Using this 2022 potential saving model, CCA building
wire would conserve 3.2 billion metric tons (7 billion
pounds) of copper resources over the next decade, not even
accounting for market growth.9, 10
2) Bimetals Provide Energy Savings
Whether electricity is generated by traditional energy sources
or by green technologies, the efficient use of energy impacts power
grid infrastructure. The more energy we require, the more
electricity we must produce. The more electricity we must produce,
the more power grid infrastructure we must build. Therefore,
reducing the amount of electricity needed reduces strain on the
power grid.
One way to more smartly use energy within a power grid network
happens at the building level. CCA conductors are the most
electrically efficient of the three building wire conductor
materials permitted by the NEC when installed per code. Recent
testing verifies that CCA conductors are 2.7% more energy efficient
than copper conductors and 7% more efficient than aluminum
conductors when installed per the NEC. This translates into
significant kilowatt hour (kWh) energy savings in the nation's
power grid.11
In 2022, total U.S. electricity consumption was about 4.05
trillion kWh. Of that, 1.42 trillion kWh (38.9%) went to the
residential sector.12 If CCA building wire's electrical
efficiency was applied to residential use alone, it would render
38.3 billion kWh of energy savings for the power grid.
That's enough annual electricity to power approximately 3.5 million
homes or a residential population the size of the city of
Chicago.13, 14
Efficient energy usage not only reduces strain on the power
grid, it translates into dollars-and-cents savings for
homeowners.
The average annual electricity consumed by a U.S. household in
2022 was 10,791 kWh (899 kWh per month).15 The resulting
average annual U.S. household electric bill was $1,644 ($137 per
month).16
Considering this data, if CCA's electrical efficiencies were
applied to 131.2 million U.S. households, the annual electric
bill savings would translate to $5.8
billion for the replacement of copper
alone.17 Savings projections are amplified once
commercial and industrial buildings are included. In these
applications, the replacement of aluminum wire with CCA in large
circuits represents the potential for substantial energy cost
savings.
Conclusion
Solid-copper wire has been the default material for electrical
circuits for over a century, so presenting change of any kind is
viewed as a threat. But, bimetals don't threaten the copper
industry; they sustain it. Bimetals allow copper to do what it does
best. With copper supply deficits threatening decarbonization and
green energy goals, finding safe and effective alternatives to
copper is critical.
Bimetallic wire reduces the use of copper in many electrical
applications, reserving copper for the periphery of the conductor,
where electrical connections are made. Using a copper-alternative
metal for the core of the wire, conductors can be engineered in
numerous ways to provide highly specialized performance. The copper
saved in the core of a wire can then be redirected to green
technology investments.
From copper conservation to energy savings to enhanced
performance, bimetallic 'Supermetals' put copper where it counts so
that society can put copper where it's needed most.
Want to learn more about Copperweld's copper-saving,
performance-enhancing bimetallic products? Contact Copperweld Sales
today.
Read the full article here.
About Copperweld
Copperweld is the world leader in bimetallic wire
and cable specializing in power, grounding, and signal conductors
for building construction, power grid, utilities, communications,
and transportation. For over 100 years, their mission has been to
make the most reliable, sustainable, and innovative wire and cable
products on the market. Copperweld's metallurgical expertise and
engineered solutions result in bimetallic products that enhance
performance, extend service life, conserve copper, improve energy
efficiency, and reduce incentives for theft. Their American-made
products are manufactured in the heart of the USA, and the culture of excellence and
innovation that inspired them over a century ago still drives them
today.
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-
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-
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- www.copperweld.com/blog/engineered-conductors
- www.copperweld.com/blog/is-ccs-really-stronger-than-copper
-
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