The energy landscape is changing at an unprecedented pace. As industries and consumers embrace electrification and utilize advanced technologies like AI, the electrical grid must evolve to meet the growing challenges introduced by this demand. According to the US Department of Energy, electricity demand is projected to grow by 15-20% over the next decade and could double by 2050.1 However, according to consulting firm ICF, this number is low due to increased data center use and industrial demand from reshoring. Their study predicts US electricity demand will rise 25% by 2030 and 78% by 2050. 2 It also highlights the fact that a significant source of growth is from “always-on” technology – data centers, AI, and cryptocurrency. This trajectory demands forward-thinking solutions to ensure reliability, efficiency, and sustainability.
Electric power utilities are responding to these challenges with large-scale capital expenditures. In 2024, 42% of these were expected to be allocated to transmission and distribution (T&D) systems. 3 This growth demonstrates the importance of key applications within the electrical grid, including transformers, switchgear, and network protectors, all of which rely on hermetic feedthroughs for dependable performance in demanding environments.
A Multi-Pronged Approach to Grid Innovation
A comprehensive strategy is essential to meet electricity generation demands. Transforming the electrical grid requires a blend of optimization, innovation, and expansion. Five ways to improve our current electrical grid include:
- Repurposing & Retrofitting Existing Infrastructure – Update and monitor legacy systems to maximize system integrity and efficiency.
- Enhancing T&D Systems – Grid hardening and modernization enhances the performance and resilience of existing systems despite increased demand.
- Scale Emerging Solutions – Expanding new grid solutions to address the increased load and accelerate grid transformation.
- Building New T&D Infrastructure – Greater demand requires all-new substations to generate and transmit electricity to support existing grids.
- Manage & Flexing Demand – leverage advanced technologies including energy storage solutions as well as distributed energy resources (DER).
Applications Shaping the Future
Hermetic feedthroughs are a critical component that supports key applications throughout the energy grid. These applications include:
- High-voltage substations
- Underground & Subsea Transmission
- Hydrogen and fuel cell systems
- Battery energy storage systems (BESS)
- Solar Inverter and distributed energy resource (DER) enclosures
- Data centers and AI infrastructure
Enabling Reliable Grid Solutions
Tailored hermetic sealing solutions are at the heart of grid reliability, protecting critical components from environmental and operational challenges. They ensure proper transmission of power, signal, and data. Douglas Electrical delivers industry-leading solutions designed to meet the dual challenge of modernizing existing infrastructure while integrating new technologies and building new sites. The core solutions are:
- DuctorSeal® Hermetic Wire Feedthroughs – ideal for upgrading legacy systems and connecting to liquid-submersed current transformers.
- StudSeal™ Hermetic Terminal Seals – designed for high-current and high-voltage applications
- CircuitSeal™ Hermetic Circuit Board Seals – helpful for condition monitoring
- OptiSeal™ Fiber Optic Feedthroughs – an additional option for real-time condition monitoring
As industrial demand for electricity grows faster than anticipated, reliable electrical connections and hermetic sealing solutions remain at the forefront of grid transformation. To explore the topic further, please check out the white paper “Empowering Grid Transformation: Sealing Solutions for the Demands of a New Energy Era.”
Resources:
1 Pathways to Commercial Liftoff (https://liftoff.energy.gov/demand growth accessed April 11, 2025: inactive June 6, 2025).
2 Rising current: America’s growing electricity demand (U.S. Demand Growth Forecast | ICF accessed June 9, 2025).
2 2025 Power and Utilities Industry Outlook (https://www2.deloitte.com/us/en/insights/industry/power-and-utilities/power-and-utilities-industry-outlook.html accessed April 11, 2025)
