21/07/2022 – Borealis and Borouge showcased at “wire” 2022
Sustainable wire and cable innovations
A wide range of innovative technologies and material solutions for wire and cable were highlighted at the booth of Borealis and Borouge at “wire” 2022. These success stories show how Borealis and Borouge’s polyolefin innovations and customer focus are helping to drive the global transition to a more sustainable energy future.
Borealis “Borlink”: the essential link in energy transition projects
As leading global innovators, Borealis and Borouge continue to provide customer-driven solutions in the wire and cable industry. The proprietary “Borlink” high voltage direct current (HVDC) technology has enabled the use of extruded cable technology to reach higher voltage and transmission levels than ever before. This increases the capacity, efficiency, and supply security of power networks. Beyond passing pre-qualification up to 640 kilovolts (kV), “Borlink” delivers superior electrical performance, and provides long-running lengths and a minimum number of joints. What is more, the cross-linked polyethylene (XLPE) material offers the additional sustainability benefit of being recyclable.
The “Borlink” HVDC technology has established an impressive track record. It has been selected for use in numerous projects, including a large-scale offshore wind farm in Jiangsu province of China, and several offshore projects have been energised in the North Sea recently.
More than 8,000 cable kilometres based on “Borlink” HVDC XLPE technology have been laid with more than 8,000 kilometres in the pipeline.
The largest ongoing “Borlink” HVDC endeavour at present is the German Corridors project. This series of underground electricity transmission lines will carry power from renewable sources, such as offshore wind farms, over hundreds of kilometres with only minimal losses. Insulated XLPE underground cables made with a fully compounded HVDC cable material based on Borlink technology, at a voltage level of 525kV, will be used in the majority of this large-scale project, specifically in the “SuedLink” and “SuedOstLink” portions.
The SuedLink has two power cable systems, each with 2 gigawatts (GW), and a cable length of over 2,500km. The northern stretch of the SuedOstLink corridor has one 2GW circuit and approximately 500km of cable. Once completed, the German Corridors will have the capacity to transport 8GW of green energy from the north to the south of Germany. This is comparable to the amount of power produced by 7-8 nuclear power reactors or as an example roughly twice the power need for Denmark.
HVC insulation grade secures Pre-Qualification Test Certifications
Another notable milestone, the Borouge-manufactured “Borlink LS4201S” has successfully passed Pre-Qualification Tests from leading test establishments, KEMA Labs and China Electric Power Research Institute (CEPRI). Passing the rigorous standards of KEMA Labs and CEPRI at 220kV validates Borouge as a reliable supplier for high voltage cables. Intended for power cable applications in high stress HV applications with rated voltage up to 230kV, “Borlink LS4201S” will meet the increasing demand for advanced high-quality energy solutions in the global market.
First-ever “Borcycle” M jacketing compound contains up to 50% post-consumer recyclate
Borealis has made great progress towards its goal of ensuring that by 2025, 100% of its consumer products are either recyclable, reusable, or made using materials from renewable sources. With the ongoing development of its first jacketing product, “Borcycle M ME7153SY”, made using material containing up to 50% post-consumer recyclate (PCR), its efforts to promote circularity now extend even deeper into its wire and cable business. This more sustainable jacketing innovation has been made possible by the proprietary “Borcycle M” technology which transforms plastic waste streams into value-added, high-performance solutions. As an ever-advancing and transformational technology for mechanical recycling, “Borcycle M” gives polyolefin-based, post-consumer waste a new life.
Preparations are currently underway for the first potential “Borcycle M” jacketing compound product launch in December 2022: “Borcycle M ME7153SY” is a natural medium-density polyethylene (MDPE), fully formulated jacketing compound. Intended for use in medium and low voltage cables, “Borcycle M ME7153SY” is easy to colour and offers good processability and smooth surface finishes. Its characteristics include good environmental stress cracking resistance (ESCR), UV resistance, and low water permeability.
Borealis pledges to become ADCA-free by 2022
The chemical compound azodicarbonamide (ADCA) is mainly used as a blowing agent in the production of polyethylene (PE) compounds used in data cables. It is classified as a Substance of Very High Concern (SVHC) by the European Chemicals Agency. Borealis has taken the decision to fully phase out all ADCA-based wire and cable products by the end of 2022.
A new ADCA-free high density polyethylene (HDPE) grade for coax cables, “Borealis HE1116”, will be introduced in 2022. Yet Borealis is already offering three ADCA-free grades to ensure that their customers have innovative and high-performing alternatives: the chemically foamed ADCA-free “Borealis HE1355” and “Borealis ME1254” grades for data cable production; and the physically foamed ADCA-free “Borealis HE4883” for data cables. Borealis is among the first in the Energy industry to commit to phasing out all ADCA-based wire and cable products, and intends to do so by the end of 2022.
“A core aspect of our ‘Ever Minds’ approach to accelerating action in the circular economy sphere is our commitment to developing more sustainable solutions that not only outperform conventional materials, but also make it possible to operate in a responsible way,” explains Bart Verheule, Borealis Global Commercial Director, Energy. “Our proprietary technologies like ‘Borlink’, ‘Borstar’, and ‘Borcycle’ are building blocks for innovation. We can even envision future Energy grades based on the ‘Bornewables’, our portfolio of premium circular polyolefin products produced with renewable feedstock that is derived 100% from waste and residue streams - with this we’re re-inventing essentials for sustainable living. We are building on our track record of bringing energy all around by offering our customers a well-rounded portfolio of pioneering and high-performance solutions on a truly global scale.”
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