Byproducts to Breakthroughs: Southwire’s Path to a Greener Future
Spark Innovation Center at Tech Square (Image: Michael Powell, Southwire)
A leader in its industry and innovation, Southwire Company, LLC, is one of North America’s largest wire and cable producers. Southwire and its subsidiaries manufacture building wire and cable, utility products, metal-clad cables, and portable electronic cord products. In addition to manufacturing, Southwire supplies assembled products, equipment, and tools and provides digital solutions like contractor planning and utility grid resiliency to its customers.
At the forefront of its innovation initiatives is the Spark Innovation Center (Spark), located in the Centergy Building here at Tech Square. Spark is a hub for research, development, and collaboration. The team at Spark engages with interns and students on projects, collaborates with startups, and leads research and development tied to Southwire’s goals of becoming a more energy-efficient company. One of Spark's most exciting projects is its work with hydrogen and graphene, a material set to revolutionize manufacturing and energy efficiency in collaboration with Levidian, a UK-based company.
Graphene can be used in various applications, from wire and cable to membrane technologies and more.
(Image: Christine Daniloff, MIT)
The Power of Graphene
Graphene is one of the most promising materials under investigation at the Spark Innovation Center. It is a single layer of carbon atoms arranged in a two-dimensional honeycomb lattice. Graphene is known for its exceptional electrical conductivity, mechanical strength, and thermal properties, which make it an ideal candidate for enhancing the performance and efficiency of electrical wire and cable products.
Southwire’s venture into graphene is driven by the material’s potential to increase conductivity, eliminate the use of harmful chemicals, and achieve its sustainability goals. The company is exploring graphene’s application in several areas, including conductive coatings and enhanced cable insulation. These innovations could lead to longer-lasting products with improved energy efficiency, aligning perfectly with Southwire’s sustainability goals.
Collaborative Innovation: Southwire and Levidian
A key component of Southwire’s work with graphene is its partnership with Levidian, a company known for its expertise in carbon nanomaterials. Together, they are exploring the decarbonization of cable production using graphene derived from methane. This process utilizes a potent greenhouse gas and transforms it into a valuable material for enhancing the properties of cables.
The collaboration with Levidian focuses on utilizing Levidian’s LOOP technology to convert natural gas into graphene and hydrogen. This innovative approach serves two sustainability goals: reducing greenhouse gas emissions and producing graphene for various wire and cable applications. The hydrogen produced is being explored as a potential fuel source, further aligning with Southwire’s sustainability objectives.
LOOP uses electromagnetic waves to ionize methane into a plasma, allowing for the separation of hydrogen and carbon without using water or producing additional CO2.
(Image: Levidian)
“Our collaboration with companies like Levidian goes beyond merely reducing our carbon footprint; it represents a transformative shift in how we approach manufacturing and materials science. Incorporating graphene into our products enhances performance and efficiency while establishing a new benchmark for sustainability within the industry.”
Pioneering New Applications for Graphene
Image: Drew Sal/Unsplash
The potential applications of graphene in Southwire’s products are vast and transformative. One of the primary areas of focus is developing conductive graphene coatings for wires and cables. These coatings could reduce electrical resistance, minimize energy loss, and improve efficiency. Such advancements are particularly relevant as the world shifts towards renewable energy sources requiring highly efficient transmission lines.
Another exciting application under exploration is the use of graphene in cable insulation. Traditional insulation materials can degrade over time, leading to energy loss and potential safety hazards. Graphene’s exceptional thermal and mechanical properties make it ideal for creating more robust, longer-lasting insulation that can withstand extreme conditions. This innovation could extend the lifespan of cables, reduce maintenance costs, and further decrease the environmental impact of cable manufacturing.
Southwire produces half of the cable used to transmit and distribute electricity in the United States and can be found in nearly one in two new homes built. Considering this, the potential for graphene is vast.
The Future of Research & Development at Spark
With its proximity to Georgia Tech and other academic institutions, Spark is strategically positioned to tap into a wealth of talent and cutting-edge research. Michael Powell, a senior engineer and key leader at Spark, notes, “Southwire chose to have Spark in Tech Square specifically because it intended for Spark to be the conduit for external knowledge and creativity outside Southwire.” This prime location enables Spark to collaborate with top academic minds, emerging startups, and students, ensuring the company stays at the forefront of industry innovation.