Energy Extraction
In energy extraction, electrical energy is converted and stored within chemical bonds or high-purity raw materials. This process occurs under extreme physical conditions. In copper refining, for example, only an absolutely uniform current distribution via specialized busbars can guarantee the purity of the end product.
Power Conductors for Industry
Busbars rated for several thousand amperes
Several thousand amperes flow in copper, aluminum, or hydrogen electrolysis, requiring systems that can handle the resulting high process heat without compromising plant safety. Any unplanned resistance leads to immense energy losses. A truly efficient, high-current power supply that makes scalable energy extraction profitable and sustainable is only possible through detailed engineering, planning, manufacturing, and installation.
Our engineers prioritize busbars
Due to their large surface area, busbars dissipate heat much more efficiently than cables do. They also allow for a more compact design of switchgear and connection areas.
Vision®Bar for Modular Efficiency: Our modular busbar systems allow for division into sections. This ensures that the power supply remains guaranteed, even if individual sections fail. Whereas bulky cable trays used to occupy valuable space, our sleek busbar systems now provide order and maximum space savings.
IndustryBars
IndustryBars for High-Performance Power: When high currents are required, our Industry Busbars are the solution. These high-performance busbars, also known as PowerBars or Busducts, are made from highly conductive materials, such as copper (Cu-ETP) or aluminum, and can be customized to your specifications.
Resilience in Harsh Environments: In the rugged environments of chemical plants and smelters, aluminum busbar systems are significantly more resistant to corrosion and mechanical stress.
Long-Term Amortization: Although copper busbars are more expensive to install initially, they pay for themselves through extremely low power losses over decades of operation.
Hydrogen electrolysis
To split water into its components, electrolyzers (PEM or alkaline) are supplied with direct current (DC). At industrial scales, the currents push conventional cable solutions to their physical limits. Busbars ensure a low-loss connection between rectifiers and stacks in these cases.
Aluminum electrolysis
Aluminum production is one of the most energy-intensive processes worldwide. Aluminum oxide is melted at high temperatures in electrolytic cells. Currents of 300 to over 500 kA are common. Even minimal resistance in the supply line would result in significant energy loss and uncontrolled heat generation.
Copper electrolysis
Precision is paramount in copper refining. To achieve a purity level of over 99.9%, the current must be distributed evenly across the anodes and cathodes. Busbars ensure consistent current flow throughout the electrolysis tanks, enabling successful energy extraction.
Precision in Contacting and Materials
The focus should be on the details, specifically the contact points. With currents in the kiloampere range, even a minor connection issue can create a hotspot that endangers the entire plant. Our modern, high-current systems use bimetallic CoppAl®(Cuponal Al/Cu), which combines the lightweight benefits of aluminum with the superior conductivity of copper.
Additionally, flexible busbars, such as braids or lamellas, are often used to compensate for thermal expansion and vibrations in electrolysis cells without putting stress on the connections. We also typically use surface finishing with silver- or tin-plated contact surfaces to minimize transition resistance.
Your Partner for Global Energy Extraction
Are you planning a project in the field of electrolysis or high-current power supply?
Energy Extraction via electrolysis is the key to a decarbonized world. However, the efficient transport of this energy within the plant is a masterpiece of engineering.
Busbars are far more than just "pieces of metal"
They are precision-manufactured, high-performance components that pave the way for green hydrogen and clean metals. Choosing the right busbar system is critical to the economic viability of your plant for the next 30 years. Contact us today to discuss your vision:
Michael Stein
Sales Manager
P +49 6307 9116 699
M +49 151 153 019 60
E mstein@ems-power.com
