WHY ALUMINIUM?
History
ALUMINIUM has very wide and varied field
of application ( space, aircraft, vehicle, electric, building, packaging, electronic,
kitchen etc..) due to its properties and lightness,it is named the METAL of the
CENTURY.
In the year 1807 Sir Humphrey Davy attempted to isolate aluminium
electrolytically, but was unsuccessful.
In the year 1812 a body of aluminium ore was discovered at Les Baux,
France. Henceforth, all ores of aluminium, no matter what their composition or where
located, are called bauxite.
In the year 1825, H.C. Oerstedt succeeded in producing small bits of
metallic aluminium.
The researchs of F.Wohler (1845), H.S.C. Deville (1854),
K.J.Meyer (1888) was issued by a patent of process. The present-day
processes was conducted in France by Paul T. Herault, and in America by Charles Martin
Hall (1892).
The first applications of the aluminium as conductor material in the electrification field
are:
In the year 1895, stranded aluminium bare conductor for overhead lines in
America and France.
In the year 1908, stranded steel reinforced aluminium bare conductor for
overhead lines.
In the year 1910, underground lead sheated cable with paper insulated
aluminium conductor at Boston and Ealing.
In the year 1912, aluminium bus bars in a ship named AQUITANA.
In the year 1917, aluminium transformer coils.
In the year 1920, aluminium squirrel-cage rotor.
Aluminium as Conductor Material
The electric power generated by various energy as thermal
(coal, fuel-oil, gas oil, natuaral gas, geothermal), hydraulic and nuclear, must be
transmitted, often over long distance, and then distributed within a city, town or an
industrial area.
Bare conductors, bus bars, insulated overhead cables and underground power cables and
connectors are the main components of the electric power transmission and distribution
systems.
The first aluminium overhead bare conductor was installed about 100 years ago. Today
aluminium is widely used in all types of cables and overhead lines of the electrification
system.
Until recently copper was the dominant conductor material for electric power
transmission and distribution because of its good properties. It has high electrical
conductivity, good workability and mechanical properties etc.
Why aluminium?
There are some powerful reasons because in numerous
countries aluminium has taken the place of copper for main
conductor material of all components of the transmision and
distribution systems.
Aluminium is much lighter than copper. the density of aluminium
is about 30 % of the copper. Especially in overhead line construction
this factor is very important because heavy conductors lead
to heavy and expensive pole structures. Handling and transportation
of aluminium conductors and cables are also easier compared
with heavy copper conductors and cables. The lightness of
aluminium gives advantages in many ways
Aluminium is the most common metal in the earth surface -
its amount is about 8 %. To day copper ores are limited and
diminishing so the price of copper has been high and rising.
The price of aluminium was low and rather steady state for
years, (See Table below), but some rising can be noticed in
it, too. Because of lightness of aluminium, the price of aluminium
conductors and cables are clearly smaller than those of copper
conductors and cables.
London Metal Exchage
(LME)
yearly average price of Copper and Aluminium
( $ / metric ton)
|
Year
|
Aluminium
$ / mton
|
Copper
$ / mton |
|
2002
(*)
|
1.339
|
1.548
|
|
2001
|
1.446
|
1.582
|
|
2000
|
1.539
|
1.815
|
|
1999
|
1.386
|
1.573
|
|
1998
|
1.358
|
1.661
|
|
1997
|
1.599
|
2.276
|
|
1996
|
1.507
|
2.302
|
|
1995
|
1.806
|
2.936
|
|
1994
|
1.477
|
2.307
|
|
1993
|
1.139
|
1.914
|
(*) until October 2002
During the last 25 years the production and
installation techniques have been developed a great deal, practical disadvantages in
aluminium cable installation techniques have been eliminated.
Technical evaluation: aluminium versa copper
Designing and installing aluminium conductors and insulated cables, including
connectors, splices and termination, is no more difficult than with copper conductors
provided, it is remembered that aluminium is a different metal than copper, both in its
physical and mechanical properties.
In the next table there can be seen some physical properties of E-Cu copper and E-Al
aluminium which are common materials for conductors and cables and also AlMgSi type
aluminium alloy, which is used in some overhead conductors and cables.
| Properties |
Unit |
E-Cu Copper |
E-Al Aluminium |
AlMgSi
Al Alloy |
| Density |
kg/dm3 |
8,9 |
2,7 |
2,7 |
| Tensile Stength
(hard... annealed) |
N/mm2 |
450...240 |
180...80 |
310 |
| Elongation at
break (hard... annealed) |
% |
1...35 |
2...35 |
3 |
| Modulus of
elasticity |
kN/mm2 |
120 |
70 |
70 |
| Melting point |
0C |
1083 |
658 |
658 |
| Coef. of thermal
expansion |
10-6
/ 0C |
16,6 |
23,8 |
23,0 |
| Temperature coef.
of resistance +20 0C |
1/ 0C
|
0,0039 |
0,0040 |
0,0036 |
| Conductivity at
+20 0C IACS |
% |
97...100 |
61...62 |
53 |
| Resistivity at +20
0C W |
mm2/m |
0,01786 |
0,02857 |
0,03280 |
Electrical
Equivalence
| Same Length |
Same Resistance |
Same Voltage Drop |
LAl = LCu |
RAl = RCu |
D UAl = D UCu |
described as above
Cu equivalent Al
(Cross-section)
Al
Resistivity |
Cu
Resistivity |
r Al = 0,028264 W mm2/m |
r Cu = 0,017857 W mm2/m |
SAl = 1,6 x SCu |
Result : Aluminium conductor
cross-section is 1,6 time bigger of Copper conductor cross-section for same
length, same resistance and same voltage drop with copper conductor.
Cu equivalent Al
(Weight)
| Density
of aluminium |
Density
of copper |
| dAl =
2,7 kg/dm3 |
dCu =
8,9 kg/dm3 |
| PAl = 0,5 x PCu |
Result : Aluminium
conductor weight is 0,5 time of Copper conductor weight for same length, same
resistance and same voltage drop with copper conductor.
If we make the comparisons between copper and aluminium
cables the values depend on size and construction of the cables.
If the properties of copper conductors are indicated with 1, then
Conditions |
Copper |
Aluminium |
| Same
cross-section |
1 |
1 |
| * Weight |
1 |
0,3 |
| * Conductivitiy |
1 |
0,625 |
| * Current
carrying capacity |
1 |
0,8 |
| Same
conductivitiy |
1 |
1 |
| * Cross
sectional area |
1 |
1,6 |
| * Diameter |
1 |
1,3 |
| * Weight |
1 |
0,49 |
| Same
temperature rise |
1 |
1 |
| * Cross
sectional area |
1 |
1,4 |
| * Diameter |
1 |
1,17 |
| * Weight |
1 |
0,42 |
Cu
equivalent Al (Economy)
For same length, same resistance and same voltage drop with
copper conductor we need for same installation half weight of equivalent
aluminium conductor and saves minimum 50 % if we accept that the price of
aluminium same as copper.
There can be seen from LME(London Metal Exchange) prices of aluminium and copper that
for more than 20 years, the price of copper is always higher than aluminium price. When
the ratio of copper and aluminum prices is bigger than 1, the saving will be bigger than
50 %.
If we import copper and aluminium as row material, we will have saving in foreign
exchange also which is important in country bases. |