Dow has announced a major step forward in high-voltage direct current (HVDC) technology with a fully qualified 525 kV insulation system, designed to meet the growing demands of modern power infrastructure. 

 

The new system expands Dow’s ENDURANCE Compounds for Cable Systems portfolio, combining insulation and semiconductive materials into a fully cross-linked XLPE solution.

 

HVDC is increasingly the technology of choice for long-distance electricity transmission, reducing losses and enabling efficient integration of renewable energy across national borders. Dow’s new system is engineered to support these modern grid challenges while boosting performance and reliability.

 

The ENDURANCE solution integrates HFDB‑4401 UDC, a fully cross-linked XLPE insulation compound, with HFDB‑0840 BK UDC, a semiconductive compound designed to reduce charge injection and space-charge accumulation. 

 

The system is engineered to operate at 90°C—compared with the conventional 70°C—unlocking higher power transmission capacity, wider operating margins, and simplified cable system design. It has been fully qualified on full-size cables, meeting the stringent standards required for HVDC applications up to 525 kV.

 

“This marks a breakthrough in high-voltage direct current (HVDC) insulation capability, as we apply our deep expertise in cross‑linked polyethylene to help customers meet evolving HVDC requirements,” said Edit Berczi, Wire & Cable global marketing manager, Packaging & Specialty Plastics, Dow. 

 

“The journey started by listening and collaborating across the value chain - from extensive testing to long‑term qualification on full‑sized cables - turning the development into a fully qualified solution designed for demanding HVDC applications.”

 

The milestone follows the successful qualification of ENDURANCE insulation and semiconductive XLPE compounds in a 525 kV HVDC submarine cable system operating at up to 90°C, confirming the solution is ready for commercial deployment.