Ningbo Shenma Group, based in Zhejiang province, has made a significant stride in the green power transmission sector. Their cutting-edge copper-aluminium composite products position the company as a global leader in enhancing power delivery systems and promise to revolutionise power transmission systems worldwide.
Bus ducts, the latest advancement in current-carrying conductors, are gaining momentum as they gradually replace traditional transmission methods in low-voltage power systems. Unlike conventional bus ducts made from pure copper or aluminium, these new composite products have a unique advantage: their superior efficiency, making them the future of power transmission.
Aluminium is often used in scenarios where high electrical conductivity is not critical, and copper, renowned for its superior conductivity, has advantages and disadvantages. Conductible Copper, in particular, plays a crucial role in the global consumption of copper, with a substantial portion dedicated to bus ducts. The introduction of Ningbo Shenma's composite products promises to enhance the efficiency and sustainability of power transmission systems worldwide.
Xu Yingchang, Chairman of Ningbo Shenma, said, "For instance, China annually consumes about 14 million tonnes of copper, with 16 per cent used for electricity, of which 30 per cent is used in bus ducts."
The high manufacturing expenses due to the dominance of copper materials, which account for over 70 per cent of bus duct costs, have long been a major obstacle to industry development. However, these challenges also present commercial opportunities for Shenma, a leading producer of aluminium discs based in Cixi, a county-level city in Ningbo.
Five years ago, Shenma leveraged its aluminium production expertise to embark on a "copper-aluminium substitution" program, investing over 30 million yuan ($4.19 million) annually in research and development. This relentless pursuit culminated in developing the industry's first copper-aluminium composite plate.
This innovative composite material, featuring a copper core sandwiched between aluminium layers, employs a unique solid-liquid cast-rolling bonding technology, creating a eutectic bond at the interface. This design reduces copper usage by nearly half—significantly cutting costs and weight—and enhances heat dissipation while maintaining excellent conductivity. With applications in power, electrical, photovoltaics, and new energy vehicles, the composite material has vast market potential.
Shenma's breakthrough has garnered widespread recognition, attracting leading international electrical brands like Schneider, ABB, and Siemens to form strategic partnerships. These companies now incorporate Shenma's copper-aluminium eutectic composite rows into their bus duct products.
"Our materials and technologies enable cost reduction and performance enhancement for our partners, which is why they collaborate with us," said Xu, a representative from Shenma.
Shenma's innovation continued further. Building upon the success of their copper-aluminium eutectic composite rows, the company introduced high-conductivity aluminium, which boasts nearly 20 per cent higher conductivity than pure aluminium while maintaining excellent tensile strength. This material, abundant in nature and economical, has also been applied to bus ducts, resulting in cost savings of over 50 per cent compared to pure copper bus ducts while offering over 60 per cent of pure copper's conductivity.
According to Xu, the dual offerings of copper-aluminium eutectic bus ducts and high-conductivity aluminium bus ducts complement each other and cater to diverse market needs.
A company in Ningbo is constructing a new 300,000-square-meter factory requiring 18,000 meters of bus ducts. It found that cables cost over RMB 30 million, while pure copper bus ducts cost RMB 24 million. However, by opting for Shenma's innovative bus ducts, the investment would only be 15 million yuan. The installation of these new bus ducts is currently underway.
Xu added, "We are confident in our ability to revolutionise the bus duct industry with our innovative solutions."
