Strengthening customer engagement
Ceres’ strategy is to form partnerships with industry leaders that will develop and sell complete product, with Ceres licensing the core fuel cell technology. This enables Ceres to access multiple geographies under the aegis of well-recognised brands, potentially accelerating product adoption. When partnering with companies with an established presence in a sector, eg Honda, Ceres would supply cells or stacks, which the partner would then integrate into their systems. When partnering with new market entrants, eg KD Navien, Ceres will supply complete power generation systems based on Steel Cell technology to help its partner evaluate the technology. However, the intention in the longer term is for these partners to use the prototype system designed by Ceres as a blueprint for developing their own variants, which they, not Ceres, will manufacture. Management aims to have five global engineering companies as customers in joint development agreements by the end of 2017 in order to achieve traction in multiple markets in the major regions across the world, with the intention of being in two commercial launch programmes by the end of 2018. The relationships with Honda, Nissan and Cummins show that it is well on the path to achieving this.
The enhancements to the Steel Cell technology that have been made over the last year (discussed on page 7) have enabled Ceres to broaden the range of applications for which the technology is suitable. Initially the technology was targeted only at the relatively low power residential CHP sector, where energy utilisation levels were boosted by capturing the heat released during electricity generation. Advances in electrical efficiency have enabled Ceres to attract partners with which it is developing Steel Cell based power generation systems for residential power only, commercial and data-centre deployments. These technical advances also improve the competitiveness of the technology compared with conventional power generation, accelerating deployment. Reductions in start-up time, combined with the ability to maintain efficiency through an increased number of power cycles, have enabled Ceres to attract partners in the automotive and back-up genset markets. We review drivers and Ceres’ position within each of these segments in turn.
Residential: Micro-CHP improves economics for householders
Japan is the most advanced country with regards to residential CHP initiatives as it is heavily dependent on imported gas to meet its energy requirements. Since 2009 the government has supported the ENE-FARM programme, which encourages the adoption of CHP fuel cells for domestic installation through the provision of subsidies. An estimated 40-50k units were shipped for the programme during 2015, the largest annual deployment to date. The majority of these were proton exchange membrane (PEM) fuel cells from Panasonic and Toshiba, the remainder SOFC from Aisin Toyota. The government goal is for 1.4m residential ENE-FARM units to be operating by 2020, 5.3m by 2030, around one tenth of all Japanese households, which is a big step up from current levels. Subsidies under the programme were extended into 2016, but at lower levels than previously. We understand that Ceres is addressing this segment through its JDA with Honda. Following a year-long evaluation of the Steel Cell technology, which concentrated on performance, robustness and ability to handle repeated power cycles, in October 2014 Ceres signed a JDA with Honda to jointly develop a fuel cell stack using the Steel Cell technology suitable for deployment in 1-5kW systems. The results from the first phase met performance targets, leading to the signature of a follow-on JDA agreement in January 2016. Ceres has developed a prototype CHP system that is smaller than any currently deployed in Japan and the only one able to meet the space constraints of a typical urban dwelling in the country. The system is also suitable for deployment in other situations where space is at a premium.
Europe – programme with British Gas
The European Commission is engaged in a smaller scale microCHP project: ene.field. This project, which ends in late 2017, targets the deployment of 1,000 proton exchange membrane fuel cell (PEMFC) and SOFC micro-CHP units. European boiler manufacturers have teamed up with suppliers of fuel cell technologies to develop systems for the project. For example German boiler giant Viessmann acquired Hexis for its SOFC technology and is partnering with Panasonic for PEMFC technology. Bosch is using SOFC technology from Aisin Seiki and BDR Thermea with Toshiba. During calendar Q416, Ceres will deliver 10 prototype home power systems to British Gas for deployment in homes and at British Gas sites. These will be used in the final phase of the EU ene.field fuel cell residential programme. The trial will confirm that the new systems, which run with existing heating, reduce the energy consumption and carbon emissions of a typical home by up to one-third and help quantify the potential cost savings. The trial will also prove that Ceres’ Steel Cell technology is ready for commercial deployment and demonstrate that the technology can be integrated into cost-effective solutions for the European market, thus encouraging OEMs to develop domestic power systems tailored for the UK/European market that incorporate Ceres’ fuel cells and stacks. These OEMs will be able to adapt Ceres’ prototype design, thus accelerating their time to market. Since these Steel Cell-based systems will be able to run on bio-gas as well as natural gas, their deployment will give British Gas a route to a decarbonised, distributed power generation solution. The availability of this solution should help the UK government achieve the dual goal of reducing carbon emissions and replacing old, centralised power generation systems without incurring the significant expenditure and risk associated with nuclear options.
Korea – engagement with KD Navien
As in Japan, the government in South Korea is actively promoting the adoption of fuel cell technology in order to reduce dependence on imported fuel. Deployment to date has primarily been for utility-scale projects using systems from Doosan or POSCO (which license fuel cell technology from US-based FuelCell Energy). However, there are 140 1kW residential units at the Hydrogen Town demonstration site in Ulsan, which shows interest in fuel cells for this application. KD Navien, Korea’s largest boiler maker, intends to address both the domestic and the international micro-CHP sector in partnership with Ceres Power. Ceres shipped a fuel cell power system to KD Navien, which successfully demonstrated superior performance for cycling and robustness compared to similar SOFC technologies. Ceres and KD Navien continue to discuss the next phase of the development programme.
Expanding residential market into non-CHP systems
Advances to the Steel Cell technology announced in December 2015, which are incorporated in the V3 Steel Cell, delivered Ceres’ stated target of over 50% net electrical efficiency. This enables the creation of fuel cell power systems for residential use that are more efficient than the best centralised generating plant when operated in power only mode (as well as achieving overall efficiency of up to 90% when operated in CHP mode).
Data centres: Programme with Cummins
Banks, telecommunications network operators, hospitals, educational and penal establishments and wastewater treatment sites are increasingly deploying fuel cells as primary or back-up power. For these applications the economic cost of not having power, estimated by the Lawrence Berkeley National Laboratory in 2009 at $14.4-173.1/kWh for medium and large commercial and industrial facilities in the US, is more significant than the comparative cost of electricity from fuel cells. The comparative cost is currently higher than that from conventional sources, but will potentially be less if Ceres is successful in taking its technology through to mass adoption. Alternative back-up systems depend on batteries, which are expensive and discharge over time, or diesel generators, which emit pollutants and are noisy, making them unsuitable for use in an urban environment. Currently Bloom Energy and Doosan are the dominant providers of high-power systems for data centres. Advances in electrical conversion efficiency mean that Ceres is now able to address these sectors. In August 2016 it announced that it was working with Cummins Inc. on a programme for the US Department of Energy (DOE) to develop a demonstration 5kW SOFC system with a target 60% electrical efficiency. It has already demonstrated 56% efficiency in initial tests of a multi-kW system. Management estimates that, if successful, the Steel Cell-based system would enable data centre operators to cut overall costs by over 20% and carbon footprint by <49%. This programme represents Ceres’ first engagement in the US.
Motive: Programme with Nissan
The key driver for the adoption of fuel cells in vehicles is the introduction of regulations reducing carbon emissions and particulate emissions from vehicles. Car manufacturers are introducing a variety of electric vehicles: fuel cell vehicles, plug-in hybrids (battery-powered electric motor plus internal combustion engine) and battery-powered vehicles. Battery-powered vehicles are more suitable for smaller cars and shorter trips because of the limited driving range (currently 100-200km for a medium-sized vehicle), while fuel cell electric vehicles offer comparable range (around 600km) to internal combustion engine vehicles and are the lowest carbon solution for medium and larger cars and longer trips. A battery-powered vehicle currently requires six to 12 hours connected to the grid for a recharge with standard charging equipment. Even rapid charging equipment takes half an hour to charge a vehicle so a public electrical charging point would need to be several times larger than a conventional petrol station to be able to refuel the same number of vehicles per day. By contrast, a fuel cell-powered vehicle can be refuelled in a similar time to a petrol vehicle.
Four things are needed for fuel cell-powered vehicles to be widely adopted:
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Vehicles need to be available commercially. This has happened. For example, both the Hyundai Tucson and the Toyota Mirai are available from dealers in California.
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Hydrogen refuelling stations needs to become widely available (for adoption of PEM fuel cell-powered vehicles). Infrastructure roll-out has commenced but is not extensive. For example ITM Power does not expect to reach 11 refuelling stations in the UK until the end of 2018, and roll-out of vehicles in California is restricted to drivers within easy reach of refuelling stations.
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The cost of fuel cell electric vehicles needs to reduce. According to Green Car Reports, the Toyota Mirai is priced at $57,500 in the US (before any subsidy).
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Fuel cell technology must not be rendered obsolete by advances in battery technology that enable manufacture of battery-powered vehicles with adequate range at a price sufficiently low for volume adoption. The production of suitable batteries still appears to be several years away. Management notes that if a significant number of new cars were to be battery powered electric vehicles, the existing electricity grid would not be able to deliver the power required. Paradoxically, homes and businesses may then need to deploy fuel cells running off mains-delivered natural gas to provide the additional electricity required.
While Ballard Power Systems, Plug Power, Hyster-Yale (which acquired Nuvera in December 2014), Intelligent Energy and Horizon Fuel Cell Technologies are involved in the sector, the first three only work with heavy vehicles where high power density is not so important. Intelligent Energy has mothballed its liquid cooled technology for larger vehicles and is concentrating on air-cooled technology suitable for primary power of motor scooters and range extenders of larger vehicles. Horizon focuses on range extenders for lightweight electric vehicles.
In March 2016 Ceres Power announced it was leading a UK government-backed consortium, including Nissan, to trial its Steel Cells with a view to extending the range of electric light commercial vehicles. Nissan is opting for SOFC rather than the PEM technology adopted by other automotive companies, as SOFC already works with natural gas rather than pure hydrogen, so should be more readily adapted for use with bio-ethanol. Bio-ethanol fuels such as those sourced from sugarcane and corn are widely available in countries in North and South America and Asia, supporting adoption of fuel cell vehicles in these regions without needing a hydrogen distribution infrastructure, as well as delivering a carbon-neutral solution. Ceres’ Steel Cell architecture is one of a small handful of SOFC technologies robust enough to withstand the thousands of power cycles demanded by an automotive application and able to start from cold and reach full power in less than 15 minutes.