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Power Up Programme

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Power Up The demonstra1on of large scale alkaline fuel cells R S Kelly December 2014 Agenda • 
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Introduc1on Challenge of waste hydrogen Fuel cell overview Power Up program Design and manufacture Summary wrap up Ques1ons December 2014 AFC Energy PLC company overview Vision To develop and produce a reliable alkaline fuel cell system at commercially acceptable prices vs. alterna1ve exis1ng energy systems How By using modern materials, design tools and manufacturing processes at scale History Formed in 2006 (listed on AIM) Well financed following 3 successful funding rounds Located close to Guildford, Surrey, UK Partners include: AkzoNobel, Air Products, Linc Energy, John Lewis December 2014 Introduc<on: • 
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Joined AFC April 2013 10 Year Hydrogen Energy Global Business Lead Career – 
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BP Chemicals SOHIO Air Products Thermal Ceramics •  Interna1onal Speaker December 2014 Chloro-­‐Alkali – surplus H2 • 
1% of the world’s electricity consump1on • 
Produces the equivalent of >£300m of electricity as surplus hydrogen a year • 
Global industry could support more than 3000 MW of genera1ng capacity AFC Energy has entered into an agreement with AkzoNobel and industrial tes1ng has already proved successful December 2014
Valorisa1on of hydrogen The 2012 situa1on unfortunately shows a further decrease compared to the previous two years with about 88% of the produced hydrogen valorised. Some companies s1ll have difficul1es to find a way to use the hydrogen by-­‐product even though new technologies, like fuel cells or electrolysers with depolarised cathodes appear on the market EuroChlor Industry Review 2013 December 2014 The Challenge •  Petrochemical plants generate excess hydrogen •  These molecules have poten1al •  Sale to Industrial Gas Companies •  Conversion to saleable products •  Vent (waste) •  Turn to steam (efficiency) •  Generate power via electrochemistry •  Fuel Cell December 2014 The Fuel Cell Dilemma •  Fuel cells are considered •  Expensive to produce •  Pt catalyst •  Bespoke specialty manufacturing •  Expensive to own and operate -­‐ •  Sensi1ve to carryover such as OH
•  Some require ppb purity •  Irrespec1ve of feedstock all rely on hydrogen •  Complex syngas prep in some cases December 2014 Fuel cell technologies… Type
Operating
Temp.*
Electrical
Efficiency*
Capital Costs
Estimated Costs
Alkaline
AFC Energy
non-platinum
70oC
55 – 60%
Less than $3.0 million
Low
Alkaline
Traditional
platinum
70oC
60%
Greater than $3.0
million
NA
Molten
Carbonate
o
600 - 700 C
45 - 47%
$4-5 million
High
Phosphoric Acid
o
150 - 200 C
40 – 50%
$4-5 million
Medium
AFC’ Alkaline Fuel Cell is a high efficiency low cost alterna1ve to PAFC and MCFC *Sources: USDoE -­‐ www.hydogen.energy.gov, www.americanhistory.si.edu December 2014 Power Up Programme First industrial deployment of AFC’s large scale KORE systems Programme goals • 
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10 December 2014 Start April 2013 Staged programme Up to 1MW per hour Equipment partner selec1on Transi1on to high volume manufacture Contract architecture developed 10 Power Up Programme "
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11 December 2014   Joint effort   FCHJU   6.0€ million EU   Matching AFC   Start April 2013   60 Months (est) 11 Power Up Programme •  The world’s largest hydrogen supply company •  Interna1onally credible & safe •  EAME, Asia, Americas, India •  Roll out of fuel cell compa1ble EfW plants •  Member of the EU funding programme December 2014 12 Power Up Programme Impact • 
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Start date for the programme is maintained as April 13 Installa<on due end of 2014 Located in Germany at Stade, north of Hamburg AP/Dow facility Full scale commercial reference for AFC Long term business poten<al Interna<onally credible partners Status • 
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H2 Agreement signed by AFC EU agreement signed by AFC Kick off mee1ng complete December 2014 13 Power Up Data Collec<on •  Power output •  On stream 1me •  Conversion rate •  Electrode life •  TCO December 2014 Extrusion – The future of electrodes Loss in Weight (Gravimetric) Feeders and Extrusion Consistency •  Raw materials individually and accurately fed by mass to an mixing barrel •  Highly reproducible Capacity •  One machine can output up to 400kW/hr. Control •  The human factor and materials exposure have been significantly reduced December 2014 Automated Assembly December 2014 Manufacturing tools Automated electrode stacking 17 December 2014 Manufacturing tools Automated extrusion of electrode layers 18 December 2014 System development 2009
Beta -­‐ 50kW 2012
2014
Alpha -­‐ 5kW KORE -­‐ 250kW December 2014
KORE – in build December 2014 AFC Advantages Stack produc1on process •  AFC uses simple and energy efficient produc1on process Hence manufacturing costs are low   Lower capital costs • MCFC: Expensive stack condi<oning:   Higher capital costs • PAFC: Highly complex stack components:   Higher capital costs December 2014 Kore assembly 22 December 2014 22 AFC Advantages – Life Cycle 6 5 4 Other FC AFC 3 Average 2 % Recycle Cost 1 0 1 2 3 4 5 6 7 8 9 10 Illustra1on only DO NOT SCALE December 2014 Installed Test Systems Two test systems installed and opera1onal in AkzoNobel, Germany December 2014 24 Robust Design DFSS •  Using mul1 component assemblies common to each unit •  Process cri1cal components are manufactured in a repe11ve environment •  This facilitates 1ghter control vs low volume bespoke op1ons •  Material selec1on •  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 effec1vely illustrate •  Low cost repeatable manufacturing of alkaline fuel cells •  Using common mul1 component assemblies •  Demonstrate the economics of preventa1ve maintenance of cartridge assemblies vs large outages •  Conversion rate of Hydrogen to power •  Up1me •  Deliver the concept of economically viable fuel cells for power genera1on •  Gaining value of waste hydrogen •  Green low cost power December 2014 Thank you for your kind a.en0on for more informa0on please visit www.afcenergy.com December 2014 
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