Our manufacturing facilities & processes

fuel-cell-componentFuelCell Energy utilizes proprietary designs and processes along with state-of-the-art manufacturing equipment to produce the fuel cell components that are the heart of our power plants. In North America, manufacturing is located in Torrington, Connecticut, USA and the facility currently has the annual capacity of 100 megawatts.

The facility completed the first of a two-phase expansion, with the first phase expanding the building. When the second phase is undertaken to add manufacturing equipment, annual capacity will be doubled to 200 megawatts. The production line is configured for continuous flow and continual improvement is a core aspect of the production process. The company’s quality management system is ISO 9001:2015 certified.

Global markets are supported by a global manufacturing presence. Production capacity is also available at a facility located in Taufkirchen, Germany.

Modular design

Fuel cell components are manufactured individually and then approximately 400 individual fuel cell components are stacked on top of each other to construct a 350 kilowatt fuel cell stack. Four fuel cell stacks are combined to build a 1.4 megawatt fuel cell module. The 1.4 MW SureSource 1500™ power plant uses one fuel cell module, while the 2.8 MW SureSource 3000™ uses two modules and the SureSource 4000 uses three modules. 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.

The SureSource 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, multiple fuel cell parks ranging between 10-20 MW in South Korea, and the world’s largest fuel cell park, a 59 megawatt facility composed of 21 SureSource 3000 power plants in Hwasung City, South Korea.