Development of Composite Insulators in Power Transmission and Distribution Under the Background of Green Energy and Sustainable Development With the rapid adoption of green energy and sustainable power solutions, composite insulators are evolving in the following key directions within transmission and distribution systems:
Technology Advancements Driven By Renewable Energy Applications
Adaptation To Higher Voltage Levels
✔ Designed for ±800kV and above UHVDC transmission in renewable energy bases (e.g., offshore wind farms, desert PV plants), featuring lightweight and low-loss designs to address the mechanical limitations of traditional porcelain insulators. ✔ Example: Silicon rubber + epoxy resin composite core rods reduce tower load by over 20%.
Resistance To Harsh Environments ✔ Salt spray/dust conditions(e.g. , coastal wind farms): Optimized shed design (e.g., deep ribs) and material formulations (e.g., hydrophobic nano-coatings), compliant with IEC 62217 salt fog tests. ✔ High-altitude/low-temperature (e.g., plateau solar farms): Development of low-temperature silicone rubber (-40°C resistant) to prevent brittleness.
DC System Applications ✔ Mitigation of charge accumulation in DC fields using conductive fillers (e.g., silicon carbide) or segmented grading rings to suppress electrical erosion.
Smart Integration And Functional Enhancements
Condition Monitoring Capabilities
✔ Embedded fiber optic sensors or RFID tags for real-time monitoring of pollution levels, mechanical stress, etc., integrated with IoT platforms (e.g., IEEE P1932.1). ✔ Case study: UK's National Grid improved fault prediction accuracy by 90% using strain sensors in composite insulators.
✔ Bio-based silicone rubber (e.g., DuPont’s Genomatica process) to reduce reliance on petroleum-derived materials. ✔ Recyclable designs: Companies like Sediver offer separable core-and-shed structures with 85% recyclability.
Low-Carbon Lifecycle Solutions ✔ Manufacturing: Use of green energy (e.g., PV-produced hydrogen for silane cracking) cuts carbon emissions by 40% versus traditional methods. ✔ Logistics: Lightweight designs reduce transport energy (1 ton of composite insulators = performance of 3 tons of porcelain insulators).
Standards And Market Trends
Evolving Standards
✔ New test requirements for renewable applications (e.g., IEC 62730-2023 adds "PID resistance testing for PV array insulators"). ✔ Under China's "dual-carbon" goals, State Grid mandates ≥60% composite insulator usage in new lines.
Improved Cost Competitiveness ✔ Mass production has reduced prices to 1.2–1.5× that of porcelain insulators, but extended lifespan (40 years vs. 25 years for porcelain) lowers LCOE by 30%.
Challenges And Countermeasures
Material Aging Research
✔ AI-accelerated simulations (e.g., Siemens' digital twin cuts testing time by 50%).
Emerging Market Competition ✔ Southeast Asian PV projects favor cost-effective Chinese composite insulators (e.g., Shenma Electric's 2023 exports grew 67%)
Composite insulators will dominate renewable energy transmission via material innovation, smart integration, and green manufacturing.
By 2030, their global market share is projected to rise from 38% (2023) to 55% (GlobalData), particularly in offshore wind and desert solar applications.
Companies must prioritize extreme-environment adaptability and circular economy designs to lead the market.
