Electrical grid operators in Europe are exploring the use of advanced composite core conductors to increase transmission capacity without the need for extensive infrastructure upgrades, a strategy gaining traction as demand surges and timelines for new construction stretch to a decade. The approach, known as reconductoring, involves replacing existing conductors with those utilizing carbon fiber composite cores, allowing for greater electricity flow and reduced energy loss.
The urgency stems from a widening gap between electricity consumption and projected demand. European Commission forecasts estimate a shortfall of approximately 900 terawatt hours by 2030, representing a quarter of last year’s total energy budget. Traditional methods of expanding grid capacity – building new power lines, towers and substations – are hampered by lengthy permitting processes, often taking eight to ten years from approval to commissioning. Renewable energy projects face similar delays, averaging five years between permission and operation.
Reconductoring offers a faster, more cost-effective alternative. By upgrading existing lines, Transmission System Operators (TSOs) can avoid the complexities and expenses associated with acquiring land, navigating regulatory hurdles, and undertaking major construction. This is particularly crucial in densely populated urban areas where space is limited and building new infrastructure is challenging.
The use of carbon fiber in these conductors is driven by the material’s exceptional lightweight and high-strength properties, as highlighted by growing interest in carbon fibre-reinforced polymers (CFRP) across various sectors. Recent research has also demonstrated the potential to manipulate carbon fiber itself using electricity, with studies showing that voltage pulses can induce reversible bending in the material. While the direct application of this research to grid infrastructure is not yet established, it points to novel possibilities in material science.
According to Exel Composites, reconductoring with carbon fiber composite cores can boost transmission capacity and reduce energy loss. The company is involved in projects across Europe aimed at modernizing aging electrical grids. The reduced planning permission requirements and streamlined execution further accelerate the process, addressing the critical need for rapid upgrades to meet the ‘Fit for 55’ targets.
The European Commission’s ‘Fit for 55’ package requires a 25 percent increase in grid capacity by 2030. Reconductoring is being positioned as a key strategy to achieve this goal, offering a viable solution to bridge the gap between current infrastructure and future energy demands. As of today, no official statement has been released regarding the extent of planned reconductoring projects across the EU.
