Power UpThe demonstration of large scale alkaline fuel cells

R S Kelly

December 2014

Agenda

• AFC new structure• AFC where it’s technology is today

– Where it’s heading by the end of 2015• European demonstration project Power Up• Foster Wheeler’s commitment• Allied’ expectations• Next Steps

December 2014

VisionTo develop and produce a reliable alkaline fuel cell system at commercially acceptable prices primarily for use in waste hydrogen streams.

HowBy using modern materials, design tools and manufacturing processes at scale

HistoryFormed in 2006 (listed on AIM)Well financed following 4 successful funding roundsLocated close to Guildford, Surrey, UKPartners include: AkzoNobel, Air Products, Linc Energy, John Lewis

AFC Energy PLCcompany overview

December 2014

Introduction:

• Joined AFC April 2013• 10 Year Hydrogen Energy• Global Business Lead• Career

– BP Chemicals– SOHIO– Air Products– Thermal Ceramics

• International Speaker

December 2014

• 1% of the world’s electricity consumption

• Produces the equivalent of >£300m of electricity as surplus hydrogen a year

• Global industry could support more than 3000 MW of generating capacity

AFC Energy has entered into an agreement with AkzoNobel and industrial testing has already proved successful

Chloro-Alkali – surplus H2

December 2014

Valorisation of hydrogen

The 2012 situation unfortunately shows a furtherdecrease compared to the previous two years withabout 88% of the produced hydrogen valorised.Some companies still have difficulties to find a wayto use the hydrogen by-product even though newtechnologies, like fuel cells or electrolysers withdepolarised cathodes appear on the market

EuroChlor Industry Review 2013

Hydrogen produced at rate 3% of Chlorine volume.

December 2014

The Challenge• Petrochemical plants generate excess hydrogen• These molecules have potential

• Sale to Industrial Gas Companies• Conversion to saleable products• Vent (waste)• Turn to steam (efficiency)• Generate power via electrochemistry

• Fuel Cell

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The Fuel Cell Dilemma• Fuel cells are considered

• Expensive to produce• Pt catalyst• Bespoke specialty manufacturing

• Expensive to own and operate• Sensitive to carryover such as OH-

• Some require ppb purity

• Irrespective of feedstock all rely on hydrogen• Complex syngas prep in some cases

December 2014

Fuel cell technologies…

TypeOperating

Temp.*Electrical Efficiency*

Capital Costs Estimated Costs

AlkalineAFC Energy

non-platinum70oC 55 – 60%

Less than $3.0 million

Low

AlkalineTraditional platinum

70oC 60%Greater than $3.0

millionNA

Molten Carbonate 600 - 700oC 45 - 47% $4-5 million High

Phosphoric Acid 150 - 200oC 40 – 50% $4-5 million Medium

*Sources: USDoE - www.hydogen.energy.gov, www.americanhistory.si.edu December 2014

AFC’ Alkaline Fuel Cell is a high efficiency low cost alternative to PAFC and MCFC

Power Up Programme

Joint effortFCHJU6.0€ million EUMatching AFCStart April 201360 Months (est)

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Power Up Programme

Joint effortFCHJU6.0€ million EUMatching AFCStart April 201360 Months (est)

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Power Up Programme

• The world’s largest hydrogen supply company

• Internationally credible & safe• EAME, Asia, Americas, India

• Roll out of fuel cell compatible EfW plants

• Member of the EU funding programme

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Power Up Programme Impact

• Start date for the programme is maintained as April 13• Installation due middle of 2015• Located in Germany at Stade, north of Hamburg AP/Dow facility• Full scale commercial reference for AFC• Long term business potential• Internationally credible partners

Status• H2 Agreement signed by AFC• EU agreement signed by AFC• Kick off meeting complete

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Power Up Data Collection

• Power output• On stream time• Conversion rate• Electrode life• TCO

December 2014

Loss in Weight (Gravimetric) Feeders and Extrusion

Extrusion – The future of electrodes

Consistency• Raw materials individually and accurately

fed by mass to an mixing barrel• Highly reproducibleCapacity• One machine can output up to 400kW/hr.Control• The human factor and materials exposure

have been significantly reducedDecember 2014

Automated Assembly

December 2014

Manufacturing toolsAutomated electrode stacking

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December 2014

Manufacturing toolsAutomated extrusion of electrode layers

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December 2014

System development

2009

2012

2014

Alpha - 5kW

Beta - 50kW

KORE - 250kW

December 2014

KORE – in build

December 2014

AFC AdvantagesStack production process

• AFC uses simple and energy efficient production process Hence manufacturing costs are low

Lower capital costs

•MCFC: Expensive stack conditioning: Higher capital costs

•PAFC: Highly complex stack components: Higher capital costs

December 2014

Kore assembly

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AFC Advantages – Life Cycle

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1 2 3 4 5 6 7 8 9 100

1

2

3

4

5

6

Other FCAFCAverage% RecycleCost

Illustration only DO NOT SCALE

Installed Test Systems

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Two test systems installed and operational in AkzoNobel, GermanyDecember 2014

Robust Design DFSS• Using multi component assemblies common to each unit

• Process critical components are manufactured in a repetitive environment• This facilitates tighter control vs low volume bespoke

options• Material selection

• e.g Low halogen Polymers• Fluid dynamics/modelling

• Minimizing gravity and PT effects at three phase boundary

December 2014

Summary• AFC’s Power Up project will effectively illustrate• Low cost repeatable manufacturing of alkaline fuel cells

• Using common multi component assemblies • Demonstrate the economics of preventative

maintenance of cartridge assemblies vs large outages• Conversion rate of Hydrogen to power• Uptime• Deliver the concept of economically viable fuel cells for

power generation• Gaining value of waste hydrogen

• Green low cost power

December 2014

Thank you for your kind attentionfor more information please visit

www.afcenergy.com

December 2014