Transgrid rolls out new technique for recycling aluminium conductors in transmission lines

Transgrid has introduced cutting-edge new equipment, a first for Australia, to speed up the recycling of obsolete transmission lines, reducing emissions and saving millions of dollars. Transgrid has teamed up with the German manufacturing company ZECK to recycle conductors in western Sydney.

The outer layer of aluminium is removed from conductors when fed into the ZECK Al/Steel Separator (ZAS) machine under tension. It is then sliced into 30-70mm pieces gathered in considerable bags in preparation for smelting into new goods. At the other end, the undamaged steel core is coiled onto a cable drum and prepared for recycling.

Newcastle-based Field Coordinator Mitch Coppock proposed the usage of the technology to Transgrid. Transgrid is the trusted and reliable operator of high-voltage energy transmission networks in New South Wales and the Australian Capital Territory.

“As a business, Transgrid is committed to embedding sustainability in all our activities and this project is just one of the ways we are working to identify and reduce our own environmental impact,” said Executive General Manager for Delivery Craig Stallan.

Before the ZAS method, old conductors had to be transported abroad to remove the outer layer of their aluminium coating so that the complete line could be recycled. Using the technique, Transgrid can reduce emissions associated with recycling conductors by up to 90 per cent.

“Everyone wins out of this solution. For Transgrid we can get a much higher return on the conductor as compared to current processes, the environment wins with reduced emissions and local businesses benefit too as they get readily available and processed aluminium. By taking out that overseas shipping we also guarantee the quality of labour that is used to process it, making it a more transparent and ethical process,” added Craig Stallan.

Transgrid may get a return of three times on scrap metal values of up to three dollars per kilogramme by cutting out the cost of offshore processing. It is anticipated to generate an additional two to three million dollars in revenue through recycling over the following three to five years.

“The trial has been successful so far. In under 2 weeks, we’ve run about 40kilometres of conductors through the machine, yielding about a kilogram of aluminium per metre of conductor. For it to start with a simple, idea and to receive the support from the business to make it happen and see it come to fruition it’s really rewarding. It just goes to show that Transgrid is always open to innovation and new ideas that will benefit how we operate,” mentioned Stallan.