Corrosion coats legacy grid infrastructure, inciting operational concerns and disruptions. Energy professionals and renewable industry experts need accessible solutions to prevent corrosion accumulation. Materials are the most reliable way to unveil the sector's next best remedy. What are the pros and cons of modern contenders, and how will energy workers employ them?
The Effects of Corrosion on Power Grids
Grid enhancements are expected to cost $2.5 trillion by 2035, demonstrating how many items need replacing and how much power needs adding. Substations need as little rust and debris covering them as possible, though corrosion is an expectation. Constant exposure to the elements has reduced infrastructure quality.
The layers cause degradation, reducing performance and efficiency in electrical output. A medley of influences makes corrosion more likely to appear:
- Moisture and condensation concentration and entrapment
- Pollutants and chemicals
- Severe weather
- Microbiologically induced corrosion
- Temperature and humidity fluctuations
- Maintenance neglect
- Low-quality paint
- Salinity
- Stray currents in the soil
- Equipment age
- Dissimilar metals used together
Grid operators and customers suffer in unique ways. The workforce experiences higher safety risks when working with corroded equipment. Machinery cannot achieve stable grounding, increasing the chances of electrocution. Preserving health and safety is crucial in the grid's next version.
For customers, reliability and connectivity are crucial. More people work from home and every device will soon have wireless connectivity. This means more products will pull power from an already strained system. Grid equipment will not handle the load if rust prevents electrical conductivity.
Corrosion-Resistant Materials
Power equipment has used the same metals for ages, and energy workers know they are effective. Corrosion-resistant materials are ideal for making anything from transmission lines to transformers. What are suitable replacements, and how could each option have room to improve? Process developments boost the grid's chances of becoming effective and sustainable.
Stainless Steel
This is one of the most corrosion-resistant materials on the market because it is austenitic. Stainless steel endures the harshest environments with its incomparable durability. It appeals to clean energy and grid expansion companies because it is widely recyclable.
Stainless steel still has room to become the perfect power grid material. The material is more expensive upfront, making the gains from the investment feel far away. It is still susceptible to some types of corrosion under acidic conditions.
Aluminum
Aluminum is the pinnacle of lightweight flexibility. It is inexpensive and malleable, making it a top choice to transport and apply in large quantities. It is also an eco-friendly alternative because of its availability and upcycle potential. It can potentially double the life expectancy of grid equipment, surpassing 70 years of operation if maintained.
It does need reinforcement or treatment to withstand galvanic corrosion. Interactivity with other metals — such as copper alloy bolts — encourages buildup. Standardizing cathodic protections and using appropriate insulation prevents joint failures caused by joining dissimilar metals.
Polymers
Energy workers have relied on polyethylene and PVC in the past to combat rust. Polymers are resistant to chemical degradation, making them multipurpose materials.
These components have a plug-and-play mentality. They are straightforward and cheap to install, making them equally ideal to retrofit and upgrade. This should not need to happen often because of their long shelf life and minimal maintenance requirements.
Polymers are not as strong as metals, though. They cannot deal with as much pressure or weight, but grid equipment is streamlining. They are versatile and take on applications needing less tensile or mechanical strength. While polymers are not vulnerable to corrosion, they are susceptible to UV damage. Research and development would need to prioritize this flaw to increase polymer viability alongside the proficiencies of different types of polymer coatings on metal surfaces.
Fiberglass-Reinforced Plastic (FRP)
FRP has the advantage of polymers with the benefit of being UV resistant. Its strength-to-weight ratio is impressive, given its notable life span. The shortcomings arise in cost and thermal distribution.
The material is one of the most expensive available. Given the scale of necessary grid upgrades, FRP may not be an approachable asset. Metals are also better equipped to handle heat dispersal. The thermal resistance of FRP is low compared to alternatives, and handling harsh temperatures is vital for meeting usage.
Galvanized Steel
Zinc coatings on galvanized steel help it withstand corrosion. Supply chains should not struggle, as the metals are readily available to most. Because most galvanized steel's power comes from the coating, it is not as strong without it. Its durability diminishes if the coating fades, so energy professionals must regularly reapply it.
Grid Challenges and Considerations
Grid upgrades are time-consuming and expensive, requiring federal aid to make the daunting project real. Regulatory actions like the Bipartisan Infrastructure Bill and U.S. Bridge Corrosion Prevention Bill are examples of what must occur to catalyze change. The legislature includes funding assistance and standards necessary to make the overhaul consistent, including guidance on corrosion resistance.
Energy workers battle the elements regularly. Climate change is intensifying, making grid work even more vulnerable to disasters. Governments must include climate change mitigation for grids, or corrosion is more likely to accumulate.
Tactics like electropolishing promise better results during fatigue testing, regardless of the environmental conditions. Silicone coatings could give a substation higher elasticity in extreme temperatures. Otherwise, the grid will not stand the test of time.
Remote maintenance equipment adds more complexity to corrosion-prevention plans. Bolstered oversight to prevent rust formation demands corrosion-prone machinery in the grid. It is critical to work with third-party makers of these sensors, software and devices to assert the urgency of corrosion prevention.
Environmental Impact and Sustainability
Corrosion has a deceptively notable carbon impact. Considering steel alone, its greenhouse gas contribution ranges between 4.1% and 9.1% of steelmaking’s footprint. Minimizing corrosion is a win for sustainability objectives. Rust on metal materials jeopardizes the grid's life span and ability to divide resources smartly. Preventing countless tons of e-waste preserves the reputation of energy and grid companies.
Lessening corrosion's presence in grid infrastructure promotes sustainability by fighting planned obsolescence. Tech is guilty of forging machines meant to perish within years. Renewable industry experts and grid professionals cannot afford to repair and replace substations every few years.
Relying on corrosion-resistant materials makes critical infrastructure greener. For example, biodegradable polymers are an option for corrosion protection. Taking corrosion out of the grid while considering a more sustainable manufacturing process is necessary for comprehensive power infrastructure decarbonization.
Implementing Corrosion Prevention With Smarter Materials
Corrosion mitigation begins with using suitable materials as grid modernization unfolds. Next-generation infrastructure must outlive and overperform historical technologies. It will increase uptime, reduce maintenance and provide better services for citizens. Grid and energy workforces must combat corrosion's impacts to promote seamless, reliable connections.