Towards achieving a neutral carbon footprint for electrical substations through multi-pronged approach

• Government incentives in the U.S. and worldwide can lead to reduction in electrical utility emissions. • Reinforcement learning techniques can generate high-strength concrete mixes with approximately 10% lower carbon footprint. • Novel R-717 Organic Rankine Cycle (ORC)-based system demonstrated to effectively harness waste heat from 235 MW power transformers • Temperature-compensated pressure sensing with trend analysis could be used for faster SF6 leak detection within a 2–3 day time horizon. • Cost-benefit of clean air HV breakers show favorable results over 30-year time horizon. The transition to carbon-conscious and ultimately towards carbon–neutral electrical substations is critical to achieving global decarbonization goals. This study explores innovative strategies to minimize the carbon footprint of electrical utility substations, focusing on material optimization, renewable integration while leveraging unused utility real estate in the vicinity of the substation, and advanced waste heat recovery. Reinforcement learning-based mix design optimization is proposed to cut the embodied carbon of concrete, a major contributor to emissions, while maintaining structural integrity. With optimized concrete design mixes, we were able to demonstrate a 10.3 % lower GWP at a comparable compressive strength and with a 10 % lower material cost. Onsite photovoltaic generation is analyzed for powering substation auxiliaries, offsetting grid dependence and resulting in potential savings in 3,500 – 3,700 tons of CO2e over a 30-year horizon. Furthermore, a novel waste heat extraction concept from substation power transformers via organic Rankine cycle systems is outlined. Using ammonia (R-717), the ORC system can harness a maximum of 247 kW of electrical power from a 235 MW large power transformer. The adoption of sulfur hexafluoride SF 6 -free alternatives, such as clean air breakers, is also evaluated over a 30-year time horizon. Despite higher upfront costs, their long-term operational and environmental benefits are substantial. By integrating these approaches, substations can significantly reduce lifecycle emissions, aligning with sustainable infrastructure development. This work provides a comprehensive framework for utilities and engineers to achieve net-zero substations, balancing technical feasibility, cost-effectiveness, and environmental impact.