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Manufacturing

fuel cell component_smState-of-the-art manufacturing facilities and processes

FuelCell Energy, Inc. employs state-of-the-art manufacturing processes and equipment to manufacture the fuel cell components that are the heart of a fuel cell power plant. The individual fuel cell components are manufactured in Torrington, Connecticut, USA using proprietary designs and processes. The production line is configured for continuous flow and continual improvement is a core aspect of the production process.

A fuel cell component manufacturing facility is under construction in Pohang, South Korea that is owned by partner, POSCO Energy. Manufacturing is expected to begin in early 2015 under a license agreement.  Additional production capacity for the assembly of sub-megawatt DFC plants is available at a facility located in Ottobrunn, Germany that is operated by FuelCell Energy Solutions, GmbH, a joint venture operated by FuelCell Energy, Inc. and Fraunhofer IKTS.

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Manufacturing facility, Torrington, Connecticut, USA

Ottobrunn Manufacturing Facility - web_sm

FuelCell Energy Solutions manufacturing facility, Ottobrun, Germany

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POSCO Energy fuel cell facility, Pohang, South Korea

Modular Design Concept

Individual fuel cell components are stacked on top of each other to build a fuel cell stack.Approximately 400 fuel cell components are used to construct each fuel cell stack.

Fuel cell stacking is performed in Torrington, Connecticut, at a POSCO Energy-owned facility in Pohang, South Korea and at the FuelCell Energy Solutions facility located in Ottobrunn, Germany.

For megawatt-class power plants, four fuel cell stacks of 350 kilowatts each are combined to build a 1.4 megawatt fuel cell module.

The 1.4 MW DFC1500 power plant uses one fuel cell module.

Two fuel cell modules are used for the 2.8 MW DFC3000 power plant.

The fuel cell module is combined with the electrical and mechanical balance of plant to complete the power plant. The mechanical balance of plant processes the incoming fuel for the fuel cells (i.e., clean natural gas or renewable biogas). The electrical balance of plant converts the direct current (DC) generated by the fuel cells into alternating current (AC) for use by the customer.

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Individual fuel cell component

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Fuel cell stack

Module - small for web

1.4 MW fuel cell module

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2.8 MW fuel cell power plant

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Multi-MW fuel cell park

The DFC power plants are scalable so that multiple plants can be combined to create multi-megawatt fuel cell parks. A number of multi-megawatt fuel cell parks are operating around the world including a 14.9 megawatt fuel cell park in Connecticut, USA, 10 MW and 11 MW fuel cell parks in South Korea and the world’s largest fuel cell park, a 59 megawatt facility composed of 21 DFC3000 power plants in Hwasung City, South Korea.