Reconductoring: Building Tomorrow’s Grid Today

June 11, 2025 by Dan Maloney 65 Comments

What happens when you build the largest machine in the world, but it’s still not big enough? That’s the situation the North American transmission system, the grid that connects power plants to substations and the distribution system, and which by some measures is the largest machine ever constructed, finds itself in right now. After more than a century of build-out, the towers and wires that stitch together a continent-sized grid aren’t up to the task they were designed for, and that’s a huge problem for a society with a seemingly insatiable need for more electricity.

There are plenty of reasons for this burgeoning demand, including the rapid growth of data centers to support AI and other cloud services and the move to wind and solar energy as the push to decarbonize the grid proceeds. The former introduces massive new loads to the grid with millions of hungry little GPUs, while the latter increases the supply side, as wind and solar plants are often located out of reach of existing transmission lines. Add in the anticipated expansion of the manufacturing base as industry seeks to re-home factories, and the scale of the potential problem only grows.

The bottom line to all this is that the grid needs to grow to support all this growth, and while there is often no other solution than building new transmission lines, that’s not always feasible. Even when it is, the process can take decades. What’s needed is a quick win, a way to increase the capacity of the existing infrastructure without having to build new lines from the ground up. That’s exactly what reconductoring promises, and the way it gets there presents some interesting engineering challenges and opportunities.

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Coin Cells: The Mythical Milliamp-Hour

December 22, 2017 by Elliot Williams 15 Comments

Just how much metaphorical juice is in a coin cell battery? It turns out that this seemingly simple question is impossible to answer — at least without a lot of additional information. The problem is that the total usable energy in a battery depends on how you try to get that energy out, and that is especially true of coin cells.

For instance, ask any manufacturer of the common 3 V lithium 2032 batteries, and they’ll tell you that it’s got 230 mAh. That figure is essentially constant across brands and across individual cells, and if you pull a constant 0.2 mA from the battery, at room temperature and pressure, you’ll get a bit more than the expected 1,150 hours before it dips below the arbitrary voltage threshold of 2.0 V. Just as it says on the tin.

What if you want to do anything else with a coin cell? Run an LED for a decade? Pull all the energy out right now and attempt to start a car? We had these sorts of extreme antics in mind when we created the Coin Cell Challenge, but even if you just want to do something mundane like run a low-power radio sensor node for more than a day, you’re going to need to learn something about the way coin cells behave in the real world. And to do that, you’re going to need to get beyond the milliamp hour rating. Let’s see how deep this rabbit hole goes.

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