Form 10-K
UNITED STATES
SECURITIES AND EXCHANGE COMMISSION
WASHINGTON, D.C. 20549
FORM 10-K
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ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE
SECURITIES EXCHANGE ACT OF 1934 |
For the fiscal year ended October 31, 2010
OR
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TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE
SECURITIES EXCHANGE ACT OF 1934 |
For the transition period from
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to
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Commission file number: 1-14204
FUELCELL ENERGY, INC.
(Exact name of registrant as specified in its charter)
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Delaware
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06-0853042 |
(State or other jurisdiction of
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(I.R.S. Employer |
incorporation or organization)
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Identification No.) |
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3 Great Pasture Road |
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Danbury, Connecticut
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06813 |
(Address of principal executive offices)
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(Zip Code) |
Registrants telephone number, including area code: (203) 825-6000
Securities registered pursuant to Section 12(b) of the Act:
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Title of each class
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Name of each exchange on which registered |
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Common Stock, $.0001 par value per share
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The Nasdaq Stock Market LLC (Nasdaq
Global Market) |
Securities registered pursuant to Section 12(g) of the Act: None
Indicate by check mark if the registrant is a well-known seasoned issuer, as defined in Rule
405 of the Securities Act. Yes o No þ
Indicate by check mark if the registrant is not required to file reports pursuant to Section
13 or Section 15(d) of the Exchange Act. Yes o No þ
Indicate by check mark whether the registrant (1) has filed all reports required to be filed
by Section 13 or 15(d) of the Securities Exchange Act of 1934 during the preceding 12 months (or
for such shorter period that the registrant was required to file such reports), and (2) has been
subject to such filing requirements for the past 90 days.
Yes þ No o
Indicate by check mark whether the registrant has submitted electronically and posted on its
corporate Web site, if any, every Interactive Data File required to be submitted and posted
pursuant to Rule 405 of Regulation S-T during the preceding 12 months (or for such shorter period
that the registrant was required to submit and post such files).
Yes o No o
Indicate by check mark if disclosure of delinquent filers pursuant to Item 405 of Regulation
S-K is not contained herein, and will not be contained, to the best of registrants knowledge, in
definitive proxy or information statements incorporated by reference in Part III of this Form 10-K
or any amendment to this Form 10-K. o
Indicate by check mark whether the registrant is a large accelerated filer, an accelerated
filer, a non-accelerated filer or a smaller reporting company. See the definitions of large
accelerated filer, accelerated filer and smaller reporting company in Rule 12b-2 of the
Exchange Act.
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Large accelerated filer o
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Accelerated filer þ
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Non-accelerated filer o
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Smaller reporting company o |
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(Do not check if a smaller reporting company) |
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Indicate by check mark whether the registrant is a shell company (as defined in Rule 12b-2 of
the Exchange Act). Yes o No þ
As of April 30, 2010, the aggregate market value of the registrants common stock held by
non-affiliates of the registrant was $198,393,984 based on the closing sale price of $2.75 as
reported on the NASDAQ Global Market.
Indicate the number of shares outstanding of each of the registrants classes of common stock,
as of the latest practicable date.
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Class |
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Outstanding at January 13, 2011 |
Common Stock, $.0001 par value per share
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123,191,914 shares |
DOCUMENTS INCORPORATED BY REFERENCE
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Document |
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Parts Into Which Incorporated |
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Annual Report to Shareholders for the Fiscal
Year Ended October 31, 2010 (Annual Report) |
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Parts I, II, and IV |
Proxy Statement for the Annual Meeting of
Shareholders to be held March 24, 2011
(Proxy Statement) |
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Part III |
FUELCELL ENERGY, INC.
INDEX
2
Forward-Looking Statement Disclaimer
When used in this report, the words expects, anticipates, estimates, should, will,
could, would, may, and similar expressions are intended to identify forward-looking
statements. Such statements relate to the development and commercialization of FuelCell Energy,
Incs. and its subsidiaries (FuelCell Energy, Company, we, us and our) fuel cell
technology and products, future funding under government research and development contracts, future
financing for projects including publicly issued bonds, equity and debt investments by investors
and commercial bank financing, the expected cost competitiveness of our technology, and our ability
to achieve our sales plans and cost reduction targets. These and other forward-looking statements
contained in this report are subject to risks and uncertainties, known and unknown, that could
cause actual results to differ materially from those forward-looking statements, including, without
limitation, general risks associated with product development and manufacturing, changes in the
utility regulatory environment, potential volatility of energy prices, government appropriations,
the ability of the government to terminate its development contracts at any time, rapid
technological change, competition and changes in accounting policies or practices adopted
voluntarily or as required by accounting principles generally accepted in the United States, as
well as other risks contained under Item 1A Risk Factors of this report. We cannot assure you
that we will be able to meet any of our development or commercialization schedules, that the
government will appropriate the funds anticipated by us under our government contracts, that the
government will not exercise its right to terminate any or all of our government contracts, that
any of our new products or technology, once developed, will be commercially successful, that our
existing DFC power plants will remain commercially successful, or that we will be able to achieve
any other result anticipated in any other forward-looking statement contained herein. The
forward-looking statements contained herein speak only as of the date of this report. Except for
ongoing obligations to disclose material information under the federal securities laws, we
expressly disclaim any obligation or undertaking to release publicly any updates or revisions to
any such statement to reflect any change in our expectations or any change in events, conditions or
circumstances on which any such statement is based.
Background
Information contained in this report concerning the electric power supply industry and the
distributed generation market, our general expectations concerning this industry and this market,
and our position within this industry are based on market research, industry publications, other
publicly available information and on assumptions made by us based on this information and our
knowledge of this industry and this market, which we believe to be reasonable. Although we believe
that the market research, industry publications and other publicly available information are
reliable, including the sources that we cite in this report, they have not been independently
verified by us and, accordingly, we cannot assure you that such information is accurate in all
material respects. Our estimates, particularly as they relate to our general expectations
concerning the electric power supply industry and the distributed generation market, involve risks
and uncertainties and are subject to change based on various factors, including those discussed
under Item 1A Risk Factors of this report.
We define distributed generation as small (typically 50 megawatts or less) electric generation
power plants (combustion-based such as engines and turbines as well as non-combustion-based such as
fuel cells) located at or near the end user. This is contrasted with central generation that we
define as large power plants (typically hundreds of megawatts to 1,000 megawatts or larger) that
deliver electricity to end users through a comprehensive transmission and distribution system.
3
As used in this report, all degrees refer to Fahrenheit (F); kilowatt (kW) and megawatt (MW)
numbers designate nominal or rated capacity of the referenced power plant; efficiency or
electrical
efficiency means the ratio of the electrical energy generated in the conversion of a fuel to the
total energy contained in the fuel (lower heating value, the standard for power plant generation,
assumes the water in the product is in vapor form; as opposed to higher heating value, which
assumes the water in the product is in liquid form, net of parasitic load); overall energy
efficiency refers to efficiency based on the electrical output plus useful heat output of the
power plant; kW means 1,000 watts; MW means 1,000,000 watts; kilowatt hour (kWh) is equal to
1kW of power supplied to or taken from an electric circuit steadily for one hour; and one British
Thermal Unit (Btu) is equal to the amount of heat necessary to raise one pound of pure water from
59oF to 60oF at a specified constant pressure.
All dollar amounts are in U.S. dollars unless otherwise noted.
Additional Technical Terms and Definitions
Alternating Current (AC) Electric current where the magnitude and direction of the current
varies cyclically, as opposed to Direct Current (DC), where the direction of the current stays
constant. The usual waveform in an AC power circuit is a sine wave, as this results in the most
efficient transmission of energy. AC refers to the form in which energy is delivered to businesses
and residences.
Anaerobic Digester Gas or Renewable Biogas Biogas produced in biomass digesters employing
bacteria in a heated and controlled oxygen environment. The biogas can be used as a renewable fuel
source for Direct FuelCells. Biomass may be generated from municipal waste water treatment
facilities, food or beverage processing or agricultural waste.
Anode An active fuel cell component functioning as a negative electrode, where oxidation of fuel
occurs. Also referred to as fuel electrode.
Availability An industry standard (IEEE (The Institute of Electrical and Electronics Engineers)
762, Definitions for Use in Reporting Electric Generating Unit Reliability, Availability and
Productivity) used to compute total period hours less the amount of time a power plant is not
producing electricity due to planned or unplanned maintenance. Availability percentage is
calculated as total period hours since commercial acceptance date (mutually agreed upon time period
when our Direct FuelCell (DFC) power plants have operated at a specific output level for a
specified period of time) less hours not producing electricity due to planned and unplanned
maintenance divided by total period hours. Grid disturbances, force majeure events and site
specific issues such as a lack of available fuel supply or customer infrastructure repair do not
penalize the calculation of availability according to this standard.
Balance of Plant (BOP) Consists of the remaining systems, components, and structures that
comprise a complete power plant or energy system that are not included in the fuel cell stack
module. We manufacture the fuel cell stack module and procure the BOP (items such as fuel
handling, processing equipment and electrical interface equipment such as inverters to convert the
fuel cell stack modules DC electricity output to AC) from third parties.
Baseload Consistent power generation that is available to meet minimum electricity demands
around-the-clock. This differs from peak or peaking power generation or load-following generation
that is designed to be turned on or off quickly to meet sudden changes in electricity demand.
Cathode An active fuel cell component functioning as a positive (electrically) electrode, where
reduction of oxidant occurs. Also referred to as oxidant electrode.
Co-generation Configuration A power plant configuration featuring simultaneous onsite generation
of electricity and recovery of waste heat to produce process steam or hot water, or to use heat for
space heating.
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Humid Flue Gas Exhaust gas from fuel cell and other power plants or a furnace. The gas
typically contains humidity (moisture).
Metallic Bipolar Plates The conductive plates used in a fuel cell stack to provide electrical
continuity from active components of one cell to those in an adjacent cell. The plates also
provide isolation of fuel and air fed to the fuel cell.
Microturbine A gas turbine with typical power output ranges of 30 kW to 350 kW. Microturbines
are characterized by low-pressure ratios (less than 5) and high-speed alternators.
Nitrogen Oxides (NOx) Generic term for a group of highly reactive gases, all of which contain
nitrogen and oxygen in varying amounts. Many of the NOx are colorless and odorless. However, one
common pollutant, Nitrogen Dioxide (NO2), along with particles in the air, can often be seen as a
reddish-brown layer over many urban areas. NOx form when fuel is burned at high temperatures, as
in a combustion process. The primary manmade sources of NOx are motor vehicles, electric
utilities, and other industrial, commercial and residential sources that burn fuels.
Particulate Matter Solid or liquid particles emitted into the air that is generally caused by the
combustion of materials or dust generating activities. Particulate matter caused by combustion can
be harmful to humans as the fine particles of chemicals, acids and metals may get lodged in lung
tissue.
Reforming Catalytic conversion of hydrocarbon fuel (such as pipeline natural gas or digester
gas) to hydrogen-rich gas. The hydrogen-rich gas serves as a fuel for the electrochemical
reaction.
Renewable Portfolio Standards (RPS) States seeking to secure cleaner energy sources are
setting standards that require utilities to provide a certain amount of their electricity from
renewable sources such as solar, wind or other biomass-fueled technologies, including fuel cells.
These standards are referred to as Renewable Portfolio Standards. Also referred to as Renewable
Energy Standard (RES) when referring to clean energy standards mandated by the U.S. government
and South Korean government.
Sulfur Oxide (SOx) Sulfur oxide refers to any one of the following: sulfur monoxide, sulfur
dioxide (SO2) and sulfur trioxide. SO2 is a byproduct of various industrial processes. Coal and
petroleum contain sulfur compounds, and generate SO2 when burned.
Synthesis Gas A gas mixture of hydrogen and carbon monoxide generally derived from gasification
of coal or other biomass. It can serve as a fuel for the fuel cell after any required fuel clean
up.
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Item 1. BUSINESS
We are a world leader in the development and production of stationary fuel cells for commercial,
industrial, government and utility customers. Our ultra-clean, high efficiency Direct
FuelCell® (DFC®) power plants are generating power at over 50 locations worldwide. Our
products have generated over 650 million kWh of power using a variety of fuels including renewable
wastewater gas, food and beverage waste, natural gas and other hydrocarbon fuels.
Our vision is to provide ultra-clean, highly efficient, reliable distributed generation baseload
power at a cost per kilowatt hour that is less than the cost of grid-delivered electricity. Our
power plants provide electricity that is priced competitively to grid-delivered electricity in
certain high cost regions of the world.
Our Company was founded in Connecticut in 1969 and reincorporated in Delaware in 1999. Our core
fuel cell products (Direct FuelCell® or DFC® Power Plants) offer highly
efficient stationary power generation for customers. In addition to our commercial products, we
continue to develop our carbonate fuel cells, planar solid oxide fuel cell (SOFC) technology and
other fuel cell technology with our own and government research and development funds.
Our proprietary carbonate DFC Power Plants electrochemically (without combustion) produce
electricity directly from readily available hydrocarbon fuels such as natural gas and biogas in a
highly efficient process. The primary byproducts of the fuel cell process are heat and water. Due
to the lack of combustion, our fuel cells emit virtually zero pollutants such as NOx, SOx or
particulate matter.
Our fuel cells operate 24 hours per day seven days per week providing reliable power to both
on-site customers and grid-support applications. Our DFC Power Plants can be part of a total
on-site power generation solution with our high efficiency products providing base load power. Our
power plants can also work in conjunction with intermittent power, such as solar or wind, or less
efficient combustion-based equipment that provide peaking and load following energy. Our products
are also well suited for meeting the needs of utility grid-support applications.
Higher fuel efficiency results in lower emissions of carbon dioxide (CO2), a major greenhouse
gas, and also results in less fuel needed per kWh of electricity generated and Btu of heat
produced. The high efficiency of the DFC Power Plant results in significantly less CO2 per unit of
power production compared to the average U.S. fossil fuel power plant. Greater efficiency reduces
customers exposure to volatile fuel costs, minimizes operating costs, and provides maximum
electrical output from a finite fuel source. DFC Power Plants achieve electrical efficiencies of
47 percent to 60 percent or higher depending on configuration, location, and application, and up to
90 percent total efficiency in combined heat and power applications.
A fuel cell power plant includes the fuel cell stack module that produces the electricity, and
balance-of-plant (BOP). The mechanical balance-of-plant processes the incoming fuel such as
natural gas or renewable biogas and includes various fuel handling and processing equipment such as
pipes and blowers. The electrical balance-of-plant processes the power generated for use by the
customer and includes electrical interface equipment such as inverters.
Our fuel cells operate on a variety of hydrocarbon fuels, including natural gas, renewable biogas,
propane, methanol, coal gas, and coal mine methane.
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Compared to other power generation technologies, our products offer significant advantages
including:
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Near-zero pollutants; |
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High efficiency; |
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Ability to site units locally as distributed power generation; |
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Potentially lower cost power generation; |
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Byproduct heat ideal for cogeneration applications; |
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High efficiency and cogeneration reduce carbon emissions |
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Reliable around-the-clock base load power; |
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Quiet operation; and |
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Fuel flexibility. |
Typical customers for our products include universities, manufacturers, mission critical
institutions such as correction facilities and government installations, hotels, natural gas
letdown stations and customers who can use renewable biogas for fuel such as municipal water
treatment facilities, breweries, and food processors. Our MW-class products are also used to
supplement the grid for utility customers. With increasing demand for renewable and ultra-clean
power options and increased volatility in electric markets, our products offer our customers
greater control over power generation economics, reliability, and emissions.
Our DFC Power Plants are protected by 61 U.S. and 66 international patents. We currently have 30
U.S. and 130 international patents under application.
2010 Update
Our strategy is focused on continuing to reduce our product costs while expanding in our key
geographic and vertical markets to grow sales volume. We believe that the combination of these two
activities will drive our path to profitability.
Order flow of 16.4 MW in 2010 illustrates the growing recognition of the need for baseload
renewable power and the need to use abundant and affordable supplies of natural gas in the U.S. as
cleanly and efficiently as possible. As renewable technologies like wind and solar are deployed
more widely, the need for clean baseload technology that complements these intermittent sources
becomes more acute, particularly baseload power that utilizes renewable biogas. The ability of DFC
Power Plants to utilize renewable biogas to efficiently produce clean electricity in a reliable
manner was a primary driver of order flow during the fourth quarter of 2010. 11.0 MW of the orders
received will operate on renewable biogas while the remaining 5.4 MW will operate on natural gas.
Fuel cells operating on natural gas are attractive for customers that value the clean power and
distributed generation attributes of fuel cells. The virtual lack of pollutants emitted by fuel
cells is important in areas with strict clean air permitting regulations such as certain regions of
California. Providing reliable on-site power generation that reduces reliance on the transmission
grid is also an important attribute of fuel cells that contributed to order activity in 2010.
During 2010, we received our first direct utility purchase in the U.S. from a major utility in
California under a rate base model. Domestic orders received in 2010 also included two 2.8 MW
DFC3000 power plants, which will be our first installations of this product in the U.S. Prior to
these two orders, the DFC3000 had only been sold in South Korea.
For several of these projects, we saw a variety of financing structures used, including traditional
project financing, bonds, grants and tax credits as well as new partners with their own sources of
capital. Our power plant projects typically cost multiple millions of dollars, have lead times
that exceed one year and have project lives that may span five years or longer. The improved
availability of capital was instrumental in closing these orders and potentially supports future
order activity.
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The 16.4 MW of orders received during 2010 were concentrated in the second half of the year, with
12.7 MW received in the fourth quarter. Orders were primarily from U.S. customers in 2010 compared
to order activity in 2009 and 2008 that included orders from POSCO Power, which we expect in 2011.
Customers, primarily POSCO Power, ordered 32.8 MW of fuel cells in fiscal 2009 and 32.3 MW in
fiscal 2008. We ended fiscal 2010 with 33.5 MW in backlog with 92 percent of the backlog
representing multi-megawatt products, modules and module kits and 8 percent of the backlog
representing sub-megawatt products. Product and service backlog totaled $154.3 million at the end
of 2010, the highest backlog ever achieved. Comparable backlog was $90.7 million in 2009 and $87.6
million in 2008.
Legislation favorable to fuel cells was passed in March, 2010 by the National Assembly of the
Republic of Korea with the adoption of a Renewable Portfolio Standard (RPS) requiring 4 percent
clean energy generation by 2015 and 10 percent by 2022. Today, only about one percent of Koreas
electricity comes from renewable resources. The South Korean government desires clean distributed
generation power sources to support their growing power needs while minimizing additional
investment and congestion of the transmission grid. Fuel cells address these needs and are
designated as an economic driver due to their ultra-clean emissions, high efficiency and reliable
distributed generation capabilities, which will help the Country achieve its RPS and electricity
generation goals.
The highly efficient Direct FuelCell-Energy Recovery Generation (DFC -ERG®) power plant, a joint
project with Enbridge Inc., (NYSE: ENB), completed its first year of operation during 2010. The
DFC-ERG plant generated very favorable operating results in the first year, having attained an
average electrical efficiency of 62.5 percent and equipment up-time of 93 percent. Although its
average electrical efficiency of 62.5 percent compares favorably to a typical conventional fossil
fuel generation of about 35 to 40 percent, the plants peak electrical efficiency topped 70 percent
in some of the scenarios under which it was evaluated. The systems high electrical efficiency
allowed it to reduce greenhouse gas emissions by up to 45 percent compared to a conventional
natural gas power plant.
The continued growth in our backlog and our production run rate is a key part of our ongoing
product cost reduction strategy. To date, our cost reduction program has successfully reduced the
unit cost of our megawatt-class products by more than 60 percent. Increased volume enables several
areas of continued cost reduction, including expansion of our global sourcing program, larger
volume purchases, more competition among our suppliers, increased utilization of our factory
capacity, and increased productivity and automation in our facilities and supply chain. As a
result of product cost reductions, we believe sales volume of 75 MW to 125 MW will drive the
Company to profitability with the lower end of the range reflecting a sales mix oriented towards
complete power plants and the upper end of the range oriented towards fuel cell components.
In response to the increased level of domestic orders received in 2010 and anticipating additional
orders from POSCO Power, we increased our production run rate to 35 megawatts per year during the
fourth quarter of fiscal year 2010. Actual production in fiscal 2010 was approximately 22 MW
compared to approximately 30 MW in 2009 and approximately 22 MW in 2008.
Our overall manufacturing process (module manufacturing, final assembly, testing and conditioning)
has a production capacity of 70 MW per year. We are expecting to continue to increase production
volume based on continued order flow. By investing $5 million to $7 million for upgrades and
maintenance of production assets, maximizing existing assets, operating at full capacity (e.g
multiple shifts 24 hours per day, up to 7 days a week) and making other improvements, we estimate
that we can increase capacity from 70 MW to 90 MW of annual production. Depending on product mix,
which would include full power plants, we may be able to reach profitability at 80 to 90 MW of
annual production.
With increasing order flow, our plan has been to expand production capacity to 150 MW within our
existing Torrington facility. This expansion would require the addition of equipment (e.g.
furnaces,
tapecasting and other equipment) to increase the capacity of certain operations. Due to the
economies of scale and equipment required, we believe it is more cost effective to add capacity in
large blocks. We estimate that the expansion to 150 MW will require additional capital investments
of $35 to $45 million although, this expansion may occur in stages depending on the level of market
demand.
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Markets
The market for alternative energy power generation continues to grow both in the U.S. and abroad
and we expect to continue to benefit from this momentum. Driving this growth are concerns about
pollutants and green house gas emissions along with the limited supply and rising cost of fossil
fuels. More than 66 percent of the worlds electric power is generated from carbon-based fossil
fuels, and this is forecasted to continue to increase for some time. With the primary source of
electric generation still driven by fossil fuels, we believe markets need new power generation
products like our fuel cells that are not only more efficient and environmentally superior, but
also cost effective and reliable.
On-Site Power
Stationary fuel cell power plants can be an economical alternative to utility-provided power and
other distributed generation products. Wastewater treatment facilities and brewery companies, for
instance, can use methane, a renewable byproduct of their own processes, to operate fuel cell power
plants. This allows them to eliminate gas flaring and the use of conventional combustion-based
power generation equipment, both of which emit pollutants such as NOx, SOx and particulate matter.
These facilities also reduce their operating costs because our fuel cell power plants can be up to
90 percent efficient when operated in combined heat and power (CHP) mode and produce
significantly more high-value electricity than competing technologies. Customers also gain the
added benefits of quiet operation and improved power reliability that on-site power generation
provides.
Utility or RPS
DFC power plants are well suited for utility grid-support due to their distributed generation
attributes. A utility can site the power plant near where power is needed, connecting to the
existing transmission grid. By producing power locally in the distribution system, our fuel cells
can ease grid constraints and also help to enable the smart grid by producing power at the point of
use. South Korea has adopted this utility-model and in 2010, a large California utility purchased
two DFC power plants.
The South Korean government desires clean distributed generation power sources to support their
growing power needs while minimizing additional investment and congestion of the transmission grid.
To meet these needs, the Government enacted a Renewable Portfolio Standard (RPS) to promote the
adoption of renewable power generation by the Nations utilities. This utility-model promotes
clean distributed generation that supports the existing transmission and distribution system. Fuel
cells address these needs and are designated as an economic driver due to their ultra-clean
emissions, high efficiency and reliable distributed generation capabilities.
A Renewable Portfolio Standard (RPS) is a mechanism designed to increase the use of renewable power
generation sources. The RPS may be voluntary or mandated through legislation and generally places
the obligation on the suppliers of electricity to generate a specified percentage of their
electricity from renewable power sources. The purpose of an RPS is to provide a market-based
mechanism that provides a competitive marketplace for providing renewable energy at the lowest
possible cost while allowing clean renewable power to compete with cheaper fossil fuels. An RPS
may even be structured to promote economic growth through adoption of renewable power generation.
Fuel cells can play a role in meeting RPS clean power mandates by generating highly efficient,
clean electricity 24 hours per day seven days per week. Fuel cells operating on renewable biogas
meet the requirements of typical RPS programs and many RPS programs include fuel cells operating on
natural gas due to the clean and highly efficient power generation process of fuel cells. Fuel
cells can balance
other forms of intermittent power generation such as wind and solar as fuel cells can be
incorporated into the electric grid infrastructure. Increased use of wind, solar and traditional
generation requires upgrades to the transmission and distribution system, whereas our fuel cells
fit into the existing grid, augmenting power where needed.
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Individual States in the U.S. seeking to secure cleaner energy sources, higher efficiency and
greater energy independence are establishing renewable portfolio standards that require utilities
to provide a certain amount of their electricity from renewable sources such as solar, wind,
biomass-fueled technologies, and fuel cells. There are currently 27 states and the District of
Columbia that have instituted RPS mandates and 5 states that have adopted non-binding renewable
energy goals. These markets represent a potential for an estimated 76,750 MW of renewable power by
2025, according to the Union for Concerned Scientists. Fuel cells using biogas fuels qualify as
renewable power generation technology in all of the RPS states, with nine states specifying that
fuel cells operating on natural gas are also eligible for these initiatives.
Business Strategy
Our business strategy is to expand our leadership position in key markets, build renewable
portfolio standards markets and continue to reduce the cost of our products. We believe a
production mix more heavily weighted with MW-class products is our fastest path to achieve
profitability. Our focus continues to be:
Build on our leadership position in geographic and vertical markets
Increased orders from our target markets will drive us to profitability. In many regions around the
world, there is growing adoption of clean, low carbon technologies. Countries are also looking to
green technologies as a way to grow their economies. This attention to clean energy technologies is
driving policy in South Korea, Europe and the U.S.
South Korea: The South Korean Government passed a Renewable Portfolio Standard (RPS) in
March 2010 that requires 4 percent clean energy generation by 2015 and 10 percent by 2022.
The program becomes effective in 2012 and will mandate 350 MW of additional renewable energy
per year through 2016, and 700 MW per year through 2022. At present, only about 1 percent
of South Koreas electricity comes from renewable resources. Fuel cells operating on
natural gas and bio gas fully qualify under the mandates of the program.
High efficiency fuel cells are an excellent green energy solution for South Korea due to the
high cost of imported fuel and the poor wind and solar profiles of the Korean Peninsula.
The South Korean government desires clean distributed generation power sources to support
their growing power needs while minimizing additional investment and congestion of the
transmission grid. Fuel cells address these needs and are designated as an economic driver
due to their ultra-clean emissions, high efficiency and reliable distributed generation
capabilities, which will help South Korea achieve its RPS and electricity generation goals.
POSCO Power, a subsidiary of South Korean based POSCO, one of the worlds largest steel
manufacturers, produces fuel cell stack modules from cells and components provided by us
under a Stack Technology Transfer and License Agreement signed in 2009. This agreement is
part of our strategy to localize certain power plant manufacturing. Locating final assembly
closer to end users reduces costs and ensures products meet the needs of individual markets.
POSCO built a 100 MW manufacturing facility in 2008 that produces balance-of-plant systems.
Demonstrating their long-term commitment to fuel cell technology and to our partnership,
POSCO began construction in April 2010 of an additional facility to assemble and manufacture
fuel cell modules with an annual capacity of 100 MW. The fuel cell stack module assembly
plant is expected to begin production in early 2011 using fuel cell components shipped from
the United States. Local capacity in South Korea effectively increases worldwide capacity
for our DFC Power Plants and demonstrates the commitment of POSCO to the DFC product line.
10
The fuel cell market in South Korea is a utility-model with fuel cell power plants
supporting the electric grid and byproduct heat generally used to create steam for heating
and cooling of nearby buildings. POSCO Power is constructing the worlds largest fuel cell
power plant in Daegu Metropolitan City, South Korea. The plant will generate 11.2 MW when
completed, utilizing four DFC3000 power plants.
In an effort to expand the market for fuel cells in South Korea, POSCO Power is funding,
under a joint development agreement with the Company that was announced subsequent to the
fiscal year ended October 31, 2010, the development of a small-scale Direct FuelCell power
plant targeted at the commercial/apartment building market in Asia. The $5.8 million
program will be funded in stages as performance milestones are reached.
California: Clean energy deployment remains a focus in California with 15.2 MW of orders
received in fiscal year 2010. These orders will utilize a variety of fuels, including
renewable biogas, directed biogas and natural gas:
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6.5 MW of power plants will be located at wastewater treatment facilities and will
utilize renewable biogas for fuel. These orders included a repeat customer as a
municipal water district chose to utilize DFC power plants at another one of their
wastewater treatment plants following an initial purchase in 2007. |
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4.5 MW of power plants will operate on directed biogas in San Diego, California
including locations at the University of California, a city-owned pump station and a
wastewater treatment plant. Renewable biogas generated from the wastewater treatment
process will be cleaned and injected into an existing gas pipeline to fuel the power
plants. |
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4.2 MW of power plants will operate on natural gas including two power plants sold
to Pacific Gas and Electric, a major utility that will site the power plants at
California universities. A 1.4 MW power plant will be located at a municipal-owned
pump station and will operate on natural gas. The favorable economic profile of the
DFC plant combined with the ability to meet current and future clean air regulations
drove the purchasing decision. |
As renewable technologies like wind and solar are deployed more widely, the need for clean
baseload technology that complements these intermittent sources becomes more acute,
particularly baseload power that utilizes renewable biogas. Municipal water treatment
operations are an attractive market opportunity as the renewable baseload power attributes
of fuel cells meet their need for clean power around-the-clock and help to solve pollutant
emission challenges. Clean air permitting is a significant hurdle in some regions of
California. Due to the electrochemical reaction that replaces combustion, virtually no
pollutants are emitted by the fuel cell, simplifying and accelerating the clean air
permitting process.
During fiscal year 2010, the 2.8 MW DFC3000 received certification under the California Air
Resources Boards distributed generation standards demonstrating the ability of the plant to
meet challenging clean air standards. The DFC3000 is the only multi-MW fuel cell to achieve
this certification. The DFC1500 and DFC300 are already certified, affirming the ultra-clean
emission profile of all FuelCell Energy products. The California Air Quality Management
Districts oversee the toughest clean air standards in the nation.
The Self-Generation Incentive Program (SGIP) adopted by the State of California
demonstrates the States commitment to reducing greenhouse gases and encouraging clean
distributed generation. Under this Program, qualifying fuel cell projects of up to 3 MW are
eligible for incentives of up to $4,500 per kilowatt when operating on renewable biogas and
up to $2,500 per kilowatt when operating on natural gas. The SGIP expires at the end of
2015.
11
A feed-in tariff (FiT) is a power-supply oriented policy designed to encourage the adoption
of renewable energy by guaranteeing a payment based on the kilowatt hours of electricity
produced for a specific period of time from the regional utility. A FiT could make it more
economically attractive to generate power using fuel cells and lead to wider deployment.
The California legislature passed bills creating two feed-in tariff programs. One bill,
AB1613 passed in 2007, created a feed-in tariff for combined heat and power projects under
which our fuel cell projects qualify. A second bill, SB32 passed in 2009, created a
separate feed-in-tariff for units operated on renewable biogas. Once the feed-in-tariffs
are fully implemented by the California Public Utilities Commission (CPUC), they could
enable fuel cell customers to sell excess electricity to the grid. The CPUC is currently
working to set pricing for these tariffs and we expect a final ruling in 2011.
To date, our focus has been on capturing certain geographic markets. The South Korean market uses
fuel cells for grid support, the California market uses fuel cells for onsite distributed
generation, and Connecticut has approved the use of fuel cells to satisfy its RPS requirements of
clean distributed generation. We expect to continue to expand geographically in the US, Canada and
Europe. As a result of success in the initial geographical markets, several FuelCell Energy
products are attracting vertical markets. Fuel cells operating on biogas are attracting worldwide
interest with their low cost fuel and ability to provide renewable baseload power.
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Wastewater Treatment / Biogas The municipal wastewater treatment market, which
utilizes renewable biogas, has immediate global potential. In California, over 50 percent
of our installed base and backlog utilize biogas produced by the wastewater treatment
process or food processing. Our units virtually eliminate pollutants, reduce CO2 and
decrease costs. The heat from our power plants is used in the anaerobic digester so in
addition to saving on electricity costs, customers save on fuel costs. This type of
combined heat and power configuration can yield efficiency up to 90 percent, depending on
the application. |
Utilities / Universities Pacific Gas and Electric, one of the largest utilities in the
United States ordered two 1.4 MW DFC1500 power plants in 2010 for installation at two
university campuses in California. The order follows an approval from the California Public
Utilities Commission (CPUC) in April 2010 for two California based utilities to purchase
fuel cells for installation at four California universities. The CPUC and the State are
leaders in the adoption of alternative energy to reduce greenhouse gases and pollution while
encouraging the utilization of distributed generation solutions that generate power at the
point of use. The CPUC approval noted the important role that fuel cells will play in the
States future energy mix.
An order received in 2010 included a 2.8 MW DFC3000 operating on directed biogas that will
be installed at a California university. Renewable biogas generated from a wastewater
treatment plant will be processed and injected into an existing gas pipeline to be used as
fuel for the DFC3000.
Universities are attracted to fuel cell generated power due to the high efficiency, reliable
baseload power and lack of pollutants that support sustainability goals. Universities can
utilize the byproduct heat to generate steam for facility heating, increasing the overall
efficiency of the power plant. Some universities incorporate fuel cell technology into
their curriculum.
12
Build Renewable Portfolio Standards Markets
RPS programs mandate that a certain percentage of electricity be generated from renewable and
ultra-clean resources. Our multi-MW products, which are scalable to utility sized installations and
our natural gas pipeline applications, are well suited to address these markets.
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Connecticut Connecticuts RPS requires utilities to purchase 20 percent of their peak
electricity needs, or about 1,000 MW, from clean power sources by 2020. During 2009,
Connecticuts Department of Public Utility Control (DPUC) finalized the selection of 27.3
MW of projects incorporating our power plants, bringing the total approved projects to 43.5
MW. All of the projects utilize our 2.8 MW DFC3000 power plants either alone or in
combination with turbines. |
Each of these projects has executed power purchase agreements with utilities. We are in
active discussions with private and government financing sources for the 43.5 MW of fuel
cell projects selected and approved by the DPUC.
Additionally, Congress is seeking solutions to address environmental problems that could result in
a federal energy bill beneficial for fuel cells. Its actions could result in a national renewable
energy standard a federal RPS and longer term, the implementation of cap and trade
policies. The Environmental Protection Agency (EPA) has recently signaled its intent to issue new
CO2 regulations. This heightened attention to the need for clean energy solutions should prove
beneficial given our products high efficiency, low CO2 emissions and near-zero regulated
emissions.
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Canada: Our DFC-ERG system, developed with our partner Enbridge Inc., is specifically
designed for natural gas pressure letdown stations. Natural gas is piped under high
pressure over long distances and the pressure must be reduced at letdown stations before it
can be distributed locally. Our fuel cell power plant is coupled with a turbo expander to
harness this energy from the letdown process that is otherwise lost. In its first full
year of operation, the DFC-ERG plant attained an average electrical efficiency of 62.5
percent, peak electrical efficiency above 70 percent, power availability of 93 percent and
reduction in greenhouse gas emissions of up to 45 percent. |
Our first DFC-ERG power plant went into operation in Toronto in 2008 and four DFC-ERG power
plants were approved by the Connecticut Department of Public Utility Control. The potential
market size has been estimated at 250 to 350 MW in just the Northeastern U.S., northern
California and Toronto, Canada.
In September 2009, the Ontario government ruled that gas distribution companies, such as
Enbridge, may own and operate power plants that generate both electricity and heat,
including fuel cells operating on natural gas, up to 10 MW per facility. This is an
essential step toward the deployment of the DFC-ERG for pipeline applications in the
province. The Ontario government is also expected to establish a revised feed-in-tariff to
encourage the installation of clean energy generation that would include stationary fuel
cells.
Continue to Reduce Product Costs
Cost reductions are essential for us to more fully penetrate the market for our fuel cell products
and attain profitability. Cost reductions will also reduce or eliminate the need for incentive
funding programs which currently allow us to price our products to compete with grid-delivered
power and other distributed generation technologies. Product cost reductions come from several
areas such as:
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engineering improvements; |
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technology advances; |
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supply chain management; |
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production volume; and |
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manufacturing process improvements. |
13
Since 2003, we have made significant progress in reducing the total life cycle costs (manufactured
cost and service costs) of our power plants primarily through value engineering our products,
manufacturing process improvements, technology improvements, and global sourcing.
2010 was the first full year of production of our lower-cost, higher-output DFC1500 and DFC3000
models incorporating 350 kW stacks, an increase from the prior 300 kW stacks. By producing more
power in a power plant, additional revenue can be attained without a commensurate increase in
production costs. As a result our products are gross margin profitable on a per unit basis. We
believe that with sufficient sales volume, production of these lower cost MW-class power plants
will move our Company to profitability. We are also developing and expect to bring to market
products with a stack life longer than five-years. Extending stack life increases the sales value
of the product and reduces service costs.
We sell complete power plants, fuel cell modules and fuel cell module kits (components). Based on
the current backlog, we expect the mix of production to be composed of a mix of fuel cell module
kits and megawatt-class power plants including the DFC1500 and DFC3000 in 2011. To date, our cost
reduction program has successfully reduced the unit cost of our megawatt-class products by more
than 60 percent. Increased volume enables several areas of continued cost reduction, including
expansion of our global sourcing program, larger volume purchases, more competition among our
suppliers, increased utilization of our factory capacity, and increased productivity and automation
in our facilities and supply chain. As a result of product cost reductions, sales volume of 75 to
125 MWs will drive the Company to profitability. The low end of this ranges require sustained
annual production primarily of our DFC3000 power plants and fuel cell modules and the high end of
the range includes a mix of fuel cell components and our DFC1500 and DFC300 power plants. Actual
results will depend on product mix, volume, mix of full power plants vs. modules only, future
service costs, and market pricing.
Products
Our core DFC Power Plant products are the 300 kW DFC300, the 1.4 MW DFC1500, and the 2.8 MW
DFC3000. Our 2.8 MW product is scalable to utility sized applications. We also manufacture and
install multi-megawatt DFC-ERG power plants for use in natural gas pipeline applications and
DFC/Turbine power plants for large load users. The DFC-ERG and DFC/Turbine power plants are our
highest-efficiency products and are nearly twice as efficient as the average U.S. central
generation fossil fuel power plant.
14
The following table shows industry estimates of the electrical efficiency, operating temperature,
expected capacity range and byproduct heat use of the principal types of fuel cells being developed
for commercial applications:
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Electrical |
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Efficiency |
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Electrical |
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With Bottom |
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Operating |
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Expected |
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Fuel Cell |
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Efficiency |
|
Cycle |
|
Temperature |
|
Capacity |
|
Byproduct Heat |
Type |
|
Electrolyte |
|
Percentage |
|
Percentage |
|
oF |
|
Range |
|
Use |
PEM
|
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Polymer
Membrane
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30-35
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NA
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180
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5 kW to
250 kW
|
|
Warm Water |
Phosphoric Acid
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Phosphoric
Acid
|
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35-40
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NA
|
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400
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|
50 kW to
400 kW
|
|
Hot Water |
Carbonate
(Direct
FuelCell®)
|
|
Potassium/Lithium
Carbonate
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45-50
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58 70
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1,200
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300 kW to
2.8 MW and
larger
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Hot water or
High Pressure
Steam |
Solid Oxide
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Stabilized Zirconium
dioxide Ceramic
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45-50
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58 70
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1,400-1,800
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3 kW to 1
MW and
larger
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Hot water or
High Pressure
Steam |
Our carbonate fuel cell, known as the Direct FuelCell, operates at approximately 1,200°F. This
temperature avoids the use of precious metal electrodes required by lower temperature fuel cells,
such as proton exchange membrane (PEM) and phosphoric acid, and the more expensive metals and
ceramic materials required by higher temperature fuel cells, such as tubular solid oxide. As a
result, we are able to use less expensive catalysts and readily available metals in our designs.
In addition, our fuel cell produces high quality byproduct heat energy (700°F) that can be
harnessed for CHP applications using hot water, steam or chiller water to heat or cool buildings.
Our Direct FuelCell is so named because of its ability to generate electricity directly from a
hydrocarbon fuel, such as natural gas or anaerobic digester gas, by reforming the fuel inside the
fuel cell to produce hydrogen. This one-step reforming process results in a simpler, more
efficient, and cost-effective energy conversion system compared with external reforming fuel cells.
External reforming fuel cells, such as PEM and phosphoric acid, generally use complex, external
fuel processing equipment to convert the fuel into hydrogen. This external equipment increases
capital cost and reduces electrical efficiency. Additionally, natural gas and anaerobic digester
gas have infrastructures that are already established. Consequently, our products are not
dependent on the development of a hydrogen delivery infrastructure.
We have established a leading position in the sale of fuel cell power plants and strengthened our
position by continuing to improve our products performance and availability, reducing costs for
our products, and expanding repeatable markets for our products. Our cumulative fleet availability
starting with the first commercial installation in 2003 is approximately 90 percent. Availability
percentage is calculated as the percentage that the power plants have operated at a specific output
level for a specified period of time less hours not producing electricity due to planned and
unplanned maintenance divided by total period hours.
Markets and Applications
The worldwide market for alternative energy power generation is growing and we expect to continue
to benefit from this momentum. More than 66 percent of the worlds electric power is generated
from carbon-based fossil fuels, and this is forecasted to continue to increase for some time.
Countries, states, provinces, cities and towns are looking for better solutions that use these
fuels more efficiently, economically and at the same time, cleanly. With the primary source of
electric generation still driven by fossil fuels, markets need new power generation products like
DFC fuel cells that are not only more efficient and environmentally superior, but also cost
effective and reliable.
15
Governments around the world, including the U.S., South Korean and many European governments, have
tied the support of green energy programs to economic growth. In the U.S., the federal investment
tax credit (ITC) is available for fuel cells in an amount up to $3,000 per kW or 30 percent,
whichever is less. Recipients can choose a tax credit or a grant, with the tax credit option
expiring December 31, 2016 and the tax grant option recently extended by the U.S. Congress expiring
December 31, 2011. This ITC grant program potentially improves the financial returns of fuel cell
projects, which is beneficial for our customers and attractive for potential customers.
In South Korea, the Ministry of Knowledge Economy designated fuel cells as a key economic driver
for the country under President Lee Myung-baks green growth plan. The efficient production of
electricity has important economic benefits for South Korea since it imports its fossil fuels.
Ultra-clean, highly efficient fuel cell power plants meet South Koreas need for increased
production of clean power with green technologies that contribute to increased domestic employment
as well as its mandate for clean energy generation. Additionally, the countrys clean energy
program requires lean electricity to be directed first to the utility grid, encouraging the
deployment of MW-class systems.
In the U.S., states seeking to secure cleaner energy sources and greater energy independence are
setting RPS mandates that require utilities to provide a certain amount of their electricity from
renewable sources such as solar, wind, biomass-fueled technologies, and fuel cells. There are
currently 27 states and the District of Columbia that have instituted RPS mandates and 5 states
that have adopted non-binding renewable energy goals. These markets represent an estimated 76,750
MW by 2025. Fuel cells using biogas fuels qualify as renewable power generation technology in all
of the RPS states, with some states and the District of Columbia specifying that fuel cells
operating on natural gas are also eligible for these initiatives.
Fuel cells can play a critical role in meeting RPS clean power mandates by generating highly
efficient, electric power around-the-clock that also balances other forms of intermittent power
generation such as wind and solar as they are incorporated into the electric grid infrastructure.
Increased use of wind, solar and traditional generation requires upgrades to the transmission and
distribution system, whereas our fuel cells fit into the existing grid, augmenting power where
needed without requiring transmission and distribution equipment upgrades. By producing base load
power locally in the distribution system, our fuel cells can ease grid constraints, making room for
additional central wind or solar power generation in the system. This distributed generation
aspect of fuel cells also helps to enable the smart grid due to the lack of reliance on the
transmission grid.
The wastewater treatment market continues to be among our strongest because our fuel cells are
particularly economical and efficient for these customers. Since our fuel cells operate on the
renewable biogas produced by the wastewater treatment process and their byproduct heat is used in
the treatment process, the efficiency of these installations can be as much as 90 percent. Fuel
cells operating on biogas qualify for incentives in all 27 RPS states and the District of Columbia
and in all 5 states with non-binding renewable energy goals.
There are currently 21 MW of our DFC Power Plants installed or in backlog for municipal water
treatment / biogas applications. Based on our installed base, market support for our products, and
our marketing focus in this area, we expect municipal water treatment facilities to continue to be
a strong market for our products.
16
Distributed Generation Markets and Applications
We compete in the distributed generation marketplace. We believe distributed generation can be a
more cost-effective solution than traditional grid-delivered electricity for the following reasons:
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Provides better economics Distributed generation avoids transmission and distribution
system investment by using the existing infrastructure close to the end user. Distributed
generation allows customers to use the heat byproduct from on-site power generation
(combined heat and power or CHP) boosting efficiency and lowering energy costs. Distributed
generation also offers the ability to control energy costs through fuel flexibility and
efficiency. For example, wastewater treatment facilities and brewery companies can use
methane, a byproduct of their own processes, to operate their fuel cell power plants. This
allows for the elimination of gas flaring and the use of conventional combustion-based
power generation equipment, both of which generate pollution. These facilities also reduce
their operating costs because our DFC Power Plants can be up to 90 percent efficient when
operated in CHP mode and produce significantly more high-value electricity than competing
technologies. Customers also gain the added benefits of quiet operation and improved power
reliability. |
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Increases reliability by locating power closer to the end user By locating smaller
power plants on-site, power generation bypasses the congested transmission and distribution
system and reduces dependence on a vulnerable centralized electrical infrastructure. |
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Eases congestion in the transmission and distribution system Each kW of on-site power
generation removes the need for the same amount from the centralized transmission and
distribution system, easing congestion that can cause power outages and hastening grid
recovery after the resolution of electrical infrastructure problems. In addition,
distributed generation provides added strength to the grid by opening up distribution
capacity for central wind or solar generation. |
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Reduces the need for new large generation and associated transmission and distribution
line investments and provides greater capacity utilization in less time On-site,
distributed generation can be added in increments that more closely match expected demand
in a shorter time frame (weeks to months) compared with traditional central power
generation plants and transmission and distribution systems (often 36 months or longer)
that require more extensive siting and right of way approvals. Siting distributed
generation can defer or avoid massive transmission and distribution investment such as
unpopular above ground high voltage lines or expensive underground high voltage lines. |
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Enables the use of more renewable fuel for power generation Distributed generation
enables end-users to use renewable biogas to generate high-efficiency, clean power, and
reduces the need for fossil fuels. |
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Promotes greater energy independence Distributed generation reduces dependence on
foreign oil and on centralized power generation, giving customers more control over their
power costs and supply. A byproduct of fuel cell power generation is high-temperature heat,
which can be used for heating and air conditioning, reducing the need for heating oil. |
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Minimizes losses in the transmission and distribution grid An estimated 6.5 percent
of central generated power is lost in the transmission and distribution grid according to
the U.S. Department of Energy. Distributed generation minimizes transmission losses,
promoting efficient power generation. |
Our fuel cell products are competitive in the marketplace because of superior product attributes
including higher operational efficiency, virtually no pollutants, lower carbon emissions
particularly when configured for combined heat and power and distributed generation. Our fuel cells
are unique among power generation technologies (including other fuel cell technologies) in that
they provide these attributes at a scale suitable to distributed generation. The only other
commercial power generation technology with electrical efficiency comparable to our products
combined cycle power plants achieves that efficiency only in sizes above 20 MWs. The fact that
fuel cells provide their high efficiency at small sizes as well as in multi-megawatt class
applications, combined with the ultra-clean and quiet
operating characteristics, makes them an ideal power generation technology for distributed
generation. While most small-scale technologies suffer from high emissions or low efficiency, our
direct fuel cells provide the efficiency of a large combined cycle power plant in a size small
enough to be located near the end user. This avoids the need to add transmission or distribution
capacity, and provides a mechanism to strengthen the existing distribution system.
17
As we reduce our product costs, we are able to price our products competitively in the markets in
which we compete. In California, for instance, factoring in the value of the heat used for
cogeneration, government incentives, and possible offsets due to emissions credits, the net cost to
the end user of our products is approximately $0.10 to $0.12/kWh, depending on location and
application, which is a level competitive with grid-delivered electricity and other distributed
generation products in our target markets. Tougher emission standards increase the cost of
competing products and as our costs continue to come down, we become increasingly competitive in
more markets.
Strategic Alliances and Market Development Agreements
Our original equipment manufacturer (OEM) and energy service company (ESCO) partners have
extensive experience in designing, manufacturing, distributing, selling and servicing energy
products worldwide. We believe our strength in the development of fuel cell products coupled with
their understanding of sophisticated commercial and industrial customers, products and services
will enhance the sales, service and product development of our products. Our strategic business
partners include:
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POSCO Power In February 2007, we signed a 10-year manufacturing and distribution
agreement with POSCO to distribute and package DFC Power Plants in South Korea. POSCO has
extensive experience in power plant project development, having built over 2,400 MW of
power plants, equivalent to 3.7 percent of South Koreas
national capacity. POSCO built a 100 MW fuel cell BOP manufacturing facility in Pohang and began
manufacturing operations in 2009. |
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In October 2009, we entered into the 2009 License Agreement allowing POSCO to manufacture
fuel cell stack modules from cell and module components provided by us. These fuel cell
modules will be combined with BOP manufactured in South Korea to complete
electricity-producing fuel cell power plants for sale in South Korea. |
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In response to the RPS, POSCO Power is investing in local fuel cell production capacity in
South Korea including a 100 MW balance of plant facility already in operation and a 100 MW
fuel cell stack module assembly plant that is expected to begin production in early 2011
using fuel cell components shipped from the United States. This localization strategy
allows FuelCell Energy to reduce costs, and ensure that products meet the needs of
individual markets. |
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We have also partnered with POSCO Power to expand the market for fuel cells in South Korea,
through development of a small-scale Direct FuelCell power plant targeted at the
commercial/apartment building market in Asia. POSCO Power will fund the development under a
joint development agreement announced subsequent to the fiscal year ended October 31, 2010.
The $5.8 million program will be funded in stages as performance milestones are reached. |
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Enbridge, Inc. We have partnered with Enbridge, a global leader in energy
transportation and distribution that includes the DFC-ERG power plant that they
co-developed with us. A 2.2 MW DFC-ERG unit was installed at Enbridges headquarters in
Toronto in 2008 and we were awarded contracts under Connecticuts Project 150 to install
18.8 MW of DFC-ERG power plants at four natural gas distribution stations, including a 9 MW
DFC-ERG installation at a natural gas letdown station in Milford, Connecticut. |
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Marubeni Corporation We are ending our alliance and distribution agreement with
Marubeni at the end of its term in June 2011. Since 2001, we have installed one 4.75 MW DFC
Power Plant with Marubeni in the Japanese market. In 2010, we entered into an agreement
with Marubeni Corporation to resolve open contractual issues and repurchase surplus
inventory items previously sold to Marubeni. |
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Energy Service Company Partners We also partner with energy service companies that
have expertise in the markets where we compete. These companies market our products.
Partners include: Alliance Power, Inc., Chevron Energy Solutions, Logan Energy Corp,
BioFuels Energy, UTS Bioenergy, and G3 Powersystems. |
18
Competition
We compete on the basis of our products reliability, fuel efficiency, environmental
considerations, and cost. We believe that our DFC carbonate fuel cells offer competitive and
environmental advantages over other fuel cell designs and combustion-based technologies for
stationary base load power generation.
Our DFC Power Plants specifically provide the following attributes that provide an advantage over
other distributed technologies of similar size:
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Higher overall efficiency and lower carbon dioxide Our DFC Power Plants are designed
to achieve an electrical efficiency of 47 percent and overall energy efficiency up to 90
percent when operated in CHP mode. The higher the electrical efficiency, the more power
generated with the least fuel, which results in lower CO2. DFC Power Plants generate only
half the CO2 of the average U.S. fossil fuel plant and near-zero NOX, SOX and particulate
matter, compared with other technologies their size. Thus when operated in CHP
applications, DFC fuel cells reduce CO2 by roughly the same amount as other distributed
generation technologies but they far surpass these technologies in reduction of NOX, SOX
and particulate matter. |
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Lower emissions Our DFC Power Plant installations emit less CO2, and near zero SOX,
NOX and particulate matter. They have been designated ultra-clean by the California Air
Resources Board (CARB), and our products are certified to CARB 2007 emissions standards.
Emissions of DFC Power Plants versus traditional combustion-based power plants are: |
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Emissions (Lbs. Per MWh) |
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NOX |
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SO2 |
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PM10 |
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CO2 |
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CO2 with CHP |
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Average U.S. Fossil Fuel Plant |
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5.06 |
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11.6 |
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0.27 |
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2,031 |
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NA |
Microturbine (60 kW) |
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0.44 |
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.008 |
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0.09 |
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1,596 |
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520 680 |
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Small Gas Turbine |
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1.15 |
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.008 |
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0.08 |
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1,494 |
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520 680 |
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DFC Power Plant |
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0.01 |
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0.0001 |
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0.00002 |
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940 |
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520 680 |
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Fuel flexibility Our DFC Power Plants can use a variety of hydro-carbon based fuel
sources, such as natural gas, renewable biogas from wastewater treatment facilities, food
processors and breweries, and coal gas (escaping gas from active and abandoned coal mines
as well as synthesis gas processed from coal). This enhances independence from imported oil
and gives customers fuel flexibility, allowing them to choose the least expensive
alternative. |
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Provide end users with greater control of their energy costs The high efficiency of
our DFC Power Plants and around-the-clock 24/7 operation gives customers predictability and
savings on energy costs. The cost of utility-provided power continues to rise and is
subject to significant volatility. Generating on-site power with known generating costs
from a DFC Power Plant gives customers a predictable component of their operations that can
be budgeted and controlled. |
Several companies in the U.S. are involved in fuel cell development, although we believe we are the
only domestic company engaged in significant manufacturing and commercialization of stationary
carbonate
fuel cells. Emerging fuel cell technologies (and companies developing them) include PEM fuel cells
(Ballard Power Systems, Inc.; United Technologies Corp. or UTC Power; and Plug Power), phosphoric
acid fuel cells (UTC Power and Samsung Everland) and solid oxide fuel cells (Siemens Westinghouse
Electric Company, General Electric, Delphi, Rolls Royce, Bloom Energy, and Acumentrics). Each of
these competitors has the potential to capture market share in our target markets.
19
There are other potential carbonate fuel cell competitors internationally. In Europe, Ansaldo Fuel
Cells in Italy is actively engaged in carbonate fuel cell development and is a potential
competitor. Fuji Electric has been involved with both PEM and phosphoric acid fuel cells. In Korea,
Doosan Corporation is engaged in carbonate fuel cell development.
Other than fuel cell developers, we must also compete with such companies as Caterpillar, Cummins,
Wartsilla, MTU Friedrichshafen GmbH (MTU), Mitsubishi Heavy Industries and Detroit Diesel, which
manufacture more mature combustion-based power generation equipment, including various engines and
turbines, and have well-established manufacturing and distribution operations along with product
operating and cost features. Electrical efficiency of these products can be competitive with our
DFC Power Plants in certain applications. Significant competition may also come from gas turbine
companies like General Electric, Ingersoll Rand, Solar Turbines and Kawasaki, which have recently
made progress in improving efficiency and reducing pollution in large-size combined cycle natural
gas fueled generators. These companies have also made efforts to extend these advantages to smaller
sizes.
We also compete against the electric grid with utilities that generate power in large
central-generation locations and then use transmission lines to transport the electricity to the
point of use.
Molten carbonate fuel cells offer attributes that can not be completely matched by any individual
competitor, including ultra-clean power generation generated in a highly efficient manner at the
point of use. Conventional fossil fuel power plants generate electricity by combustion of
hydrocarbon fuels, such as coal, oil, or natural gas. With reciprocating engines, fuel combustion
takes place within the engine that drives a generator that produces electricity. In a gas turbine
combined cycle plant, fuels, such as natural gas, are burned in the gas turbine, which drives a
generator. The exhaust heat from the gas turbine is used to boil water, which converts to
high-pressure steam and used to rotate a steam turbine generating additional electricity. The
combustion process typically creates emissions of SOX, NOX, CO2, carbon monoxide, particulates and
other air pollutants.
Manufacturing
Manufacturing Process
We have a 65,000 square foot manufacturing facility in Torrington, Connecticut where we produce our
repeating fuel cell components: the anode and cathode electrodes, metallic bipolar plates and the
electrolyte matrix. These stack components are combined and assembled into fuel cell modules. The
completed modules are then transported to our test and conditioning facilities in Danbury,
Connecticut and then shipped to customer sites for installation with the BOP that has been shipped
separately.
Our manufacturing strategy is to commit our capital to manufacturing the critical core fuel cell
components. The components of the BOP are either purchased directly from suppliers or the
manufacturing is outsourced based on our designs and specifications.
Capacity and Production Ramp-up
Our overall manufacturing process (module manufacturing, final assembly, testing and conditioning)
has a production capacity of 70 MW per year. We are expecting to continue to increase production
volume based on continued order flow. By investing $5 million to $7 million for upgrades and
maintenance of production assets, maximizing existing assets, operating at full capacity (e.g
multiple shifts 24 hours per
day, up to 7 days a week) and making other improvements, we estimate that we can increase capacity
from 70 MW to 90 MW of annual production.
With increasing order flow, our plan has been to expand production capacity to 150 MW within our
existing Torrington facility. This expansion would require the addition of equipment (e.g.
furnaces, tapecasting and other equipment) to increase the capacity of certain operations. Due to
the economies of scale and equipment required, we believe it is more cost effective to add capacity
in large blocks. We estimate that the expansion to 150 MW will require additional capital
investments of $35 to $45 million although, this expansion may occur in stages depending on the
level of market demand.
20
Raw Materials and Supplier Relationships
We use various raw materials and components to construct a fuel cell module, including nickel and
stainless steel which are critical to our manufacturing process. Our fuel cell stack raw materials
are sourced from multiple vendors and are not considered precious metals In addition to
manufacturing the fuel cell module in our Torrington facility, the electrical BOP and mechanical
BOP are assembled by and procured from several key suppliers. All of our suppliers must undergo a
qualification process, which generally takes from four to twelve months. We continually evaluate
new suppliers and are currently qualifying several new suppliers.
Service and Warranty Agreements
We offer comprehensive service and maintenance programs including total fleet management,
refurbishment and recycling services and complete product support including spare parts inventory.
In addition to the standard product warranty of one year, we also offer customers long-term service
agreements (LTSA) for fuel cell power plants ranging from one to 20 years. Our standard LTSA term
is five years and may be renewed if the parties mutually agree on future pricing. Pricing for
service contracts is based upon the markets in which we compete as well as estimates of future
costs.
Customer service is supported by our Global Technical Assistance Center (GTAC), located at the
Companys Danbury, Connecticut headquarters. From this state-of-the-art facility, trained
technicians remotely monitor DFC power plants around the world. GTAC technicians are available 24
hours a day seven days per week, 365 days per year to respond to customer inquiries, order
replacement parts, or schedule a service call from one of our regional service teams. We have also
established parts warehouses that include spare fuel cell stacks in Connecticut, California and
Asia. We have fully equipped regional field service teams, stack repair/refurbishment centers
located in Connecticut and South Korea, and testing and conditioning facilities located in
Connecticut. All personnel complete an operator and maintenance technician training program and
work closely with the engineering and technology support organizations to service our products in
the field. This infrastructure has enabled us to diagnose issues quickly, maintain high product
availability and ensure customer satisfaction.
Under the standard provisions of the LTSAs, we provide services to maintain, monitor, and repair
customer power plants to meet minimum operating levels. Should the power plant not meet the minimum
operating levels, we may be required to replace the fuel cell stack with a new or used replacement
or pay performance penalties. Our contractual liability under LTSAs is limited to amount of service
fees payable under the contract. This can often times be less than the cost of a new stack
replacement. However, in order to continue to meet customer expectations, we may incur costs in
excess of our contractual liabilities.
Power Purchase Agreements
Power purchase agreements (PPAs) are a common arrangement in the energy industry, whereby a
customer purchases power from an owner and operator of the power generation equipment. A number of
our partners such as Alliance Power, BioFuels Energy or UTS
Bioenergy enter into PPAs with end users in the U.S. After purchasing DFC Power Plants from us, they own and operate the units.
When we began installing our early version power plants, we seeded the market with a few PPAs to
penetrate key target markets and develop operational and transactional experience. To date, we
funded the development and construction of certain fuel cell power plants sited near customers in
California, and own and operate 2.5 MW of assets through joint ventures in which we have an 80
percent ownership interest. As we enter into multi-megawatt projects in RPS markets with the
benefit of the federal ITC and accelerated depreciation, we believe future PPAs will attract third
party financing and ownership. This has begun to happen as three different transactions totaling
8.7 MW were closed in October 2010 that involved PPAs with third party ownership. In each
project, we sold our power plants to a third party that will own and operate the plants and sell
the electricity under long term PPAs to the power user.
21
Research and Development
We perform both customer-sponsored and company-funded research and development projects. The goal
of our research and development efforts is to improve our core products and expand our technology
portfolio in complementary high temperature fuel cell systems. In addition, we are conducting
development work on advanced applications for other fuel cell technologies, including SOFC and PEM.
The cost of customer sponsored research and development is classified as cost of research and
development contracts in our consolidated financial statements. We also fund our own research and
development projects including extending module life, increasing the power output of our modules
and reducing the cost of our products. Company-funded research and development is included in
research and development expenses in our consolidated financial statements. For the fiscal years
ended 2010, 2009, and 2008, total customer-sponsored and company-funded research and development
costs and expenses were $28.9 million, $30.2 million, and $39.5 million, respectively.
Government Research & Development Contracts
Since 1975, we have worked on the development of our DFC technology with various U.S. government
departments and agencies, including the Department of Energy (DOE), the Department of Defense
(DOD), the Environmental Protection Agency (EPA), the Defense Advance Research Projects Agency
(DARPA) and the National Aeronautics and Space Administration (NASA). Government funding,
principally from the DOE, provided 15 percent, 16 percent, and 17 percent of our revenue for the
fiscal years ended 2010, 2009, and 2008, respectively. From the inception of our carbonate fuel
cell development program in the mid-1970s to date, more than $550 million has been invested
relating to government programs in support of the development of our DFC and related technologies.
Research and development programs are building on the versatility of our fuel cell power plants and
contributing to the development of potentially new end markets. Our power plants can provide three
value streams including clean electricity, high quality usable heat and hydrogen. The hydrogen can
be used for vehicle refueling or industrial purposes. Significant research and development
programs we are currently working on include:
Co-production of Hydrogen and Electricity using DFC Power Plants Our high temperature DFC power
plant generates electricity directly from a hydrocarbon fuel by reforming the fuel inside the fuel
cell to supply hydrogen for the fuel cell electrical generation process. Gas separation technology
can then be added to capture hydrogen that is not used by the electrical generation process, and we
term this configuration DFC-H2. This value-added proposition may be compelling for industrial users
of hydrogen. It also provides a technology bridge to the hydrogen infrastructure under development
by the DOE in our nations bid for greater energy independence.
Advanced Hydrogen Programs: The demonstration DFC-H2 power plant generates ultra-clean electricity
and hydrogen for industrial and transportation uses.
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A DFC300-H2 power plant is operating at a wastewater treatment facility in Los Angeles,
California to supply 1) hydrogen for use in fuel cell vehicle refueling, 2) clean
electricity, and 3) high quality heat for the wastewater treatment process. The plant
began operating on natural gas during the fourth quarter of 2010 and is expected to be
operational on renewable biogas by early 2011. The demonstration is being performed under
sub-contract to Air Products (NYSE: APD) with the majority of funding provided by the DOE. |
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In 2010, we were awarded approximately $2.8 million by the DOE to demonstrate the
hydrogen production capacity of a 300 kilowatt DFC300 fuel cell for use by the metal
processing industry. A DFC300-H2 will be configured to generate three value streams
including: 1) hydrogen for use in a heat treating process, 2) clean electricity, and 3)
high quality heat. Over 600 companies operate in the metal processing industry in the USA,
representing a significant potential market for this demonstration product. |
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The DOE awarded us approximately $2.0 million in 2010 to further develop and demonstrate
a highly efficient and reliable method for compressing hydrogen utilizing our solid-state
Electrochemical Hydrogen Compressor (EHC) technology. The EHC technology can be utilized
to compress hydrogen for storage, transport and subsequent use for vehicle refueling or
other industrial applications. |
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SECA and Large Scale Hybrid Programs We are currently participating in Phase II of the DOEs
Solid State Energy Conversion Alliance (SECA) Large Scale Hybrid Program. The goal of the program
is to develop a multi-MW, highly efficient, central generation SOFC power plant operating on coal
syngas. Phase I of the program was a two-year, $32.3 million cost-shared program. Phase II,
awarded in fiscal 2009 is a $30.2 million program which began in January 2009 and is nearing
completion. We have submitted a bid for approximately $34 million to the DOE for Phase III and
expect a decision in early 2011.
We utilize the cell and stack design of our technology team partner, Versa Power Systems Inc.
(Versa), for our SOFC development programs. We currently own approximately 39% of Versa. Versa
has been engaged in SOFC development since 1997 and is considered a world leader in SOFC cell and
stack technology. We have been a prime contractor in the SECA program since 2003.
The FuelCell Energy/Versa team has met cost and performance objectives for a minimum 25 kW fuel
cell stack in Phase II of the program. The full scale advanced fuel cell system to be demonstrated
in Phase III is expected to incorporate an SOFC module with an output of up to 250 kW of
ultra-clean grid electrical power. Accomplishing these Phase III goals will require selection by
DOE for SECA Phase III, along with continued availability of DOE and cost-share funding.
The goal of this multi-phased program is to develop an advanced fuel cell system with overall
efficiency of at least 50 percent in converting energy contained in coal to ultra-clean grid
electrical power. In contrast, todays average U.S. coal-based power plant has an electrical
efficiency of approximately 33 percent. In addition, the envisioned SOFC-hybrid system is expected
to separate 90 percent or more of the systems CO2 emissions for capture and environmentally safe
disposal while being cost competitive with other base load power generating technologies.
Government Regulation
Our Company and its products are subject to various federal, state and local laws and regulations
relating to, among other things, land use, safe working conditions, handling and disposal of
hazardous and potentially hazardous substances and emissions of pollutants into the atmosphere.
Emissions of SOX and NOX from our power plants are much lower than conventional combustion-based
generating stations, and are well within existing and proposed regulatory limits. The primary
emissions from our power plants, assuming no cogeneration application, are humid flue gas that is
discharged at temperatures of 700-800°F, water that is discharged at temperatures of 10-20°F above
ambient air temperatures, and CO2
in per kW hour amounts much less than conventional fossil fuel central generation power plants. In
light of the high temperature of the gas emissions, we are required to site or configure our power
plants in a way that will allow the gas to be vented at acceptable and safe distances. The
discharge of water from our power plants requires permits that depend on whether the water is to be
discharged into a storm drain or into the local wastewater system. Lastly, as with any use of
hydrocarbon fuel, the discharge of emissions must meet emissions standards. While our products have
very low carbon monoxide emissions, there could be additional permitting requirements in smog
non-attainment areas with respect to carbon monoxide if a number of our units are aggregated
together.
23
We are also subject to federal, state, provincial or local regulation with respect to, among other
things, emissions and siting. In addition, utility companies and several states have created and
adopted or are in the process of creating interconnection regulations covering both technical and
financial requirements for interconnection of fuel cell power plants to utility grids.
Proprietary Rights and Licensed Technology
To compete in the marketplace, align effectively with business partners, and protect our
proprietary rights, we rely primarily on a combination of trade secrets, patents, confidentiality
procedures and agreements, and patent assignment agreements. We have 61 current U.S. patents
(including one allowed in September 2010 by the U.S. Patent and Trademark Office for which issue is
pending) and 66 international patents covering our fuel cell technology (in certain cases covering
the same technology in multiple jurisdictions). Fifty-nine of our U.S. patents relate to our Direct
FuelCell technology and two patents relate to PEM fuel cell technology. We also have submitted 30
U.S. and 130 international patent applications.
Our patents will expire between 2011 and 2029, and the current average remaining life of our
patents is approximately 11.2 years. During 2010, six new U.S patents were issued or allowed
(including the patent allowed in September 2010) and three U.S. and 16 international patents
expired or were abandoned. The expiration of these patents has no material impact on our current
or anticipated operations. We also have approximately 34 invention disclosures in process with our
patent counsel that may result in additional patent applications.
Many of our U.S. patents are the result of government-funded research and development programs,
including our DOE programs. U.S. patents that we own that resulted from government-funded research
are subject to the government exercising march-in rights. We believe that the likelihood of the
U.S. government exercising these rights is remote and would only occur if we ceased our
commercialization efforts and there was a compelling national need to use the patents.
We have also entered into certain license agreements through which we have obtained the rights to
use technology developed under joint projects. Through these agreements, we must make certain
royalty payments on the sales of products that contain the licensed technology, subject to certain
milestones and limitations.
24
Significant Customers and Backlog
We contract with a small number of customers for the sale of our products and for research and
development contracts. For the fiscal years ended October 31, 2010, 2009 and 2008, our top three
customers, POSCO, which is a related party and owns approximately 10 percent of the outstanding
common shares of the Company, the U.S. government (primarily the Department of Energy) and Pacific
Gas and Electric, accounted for 83 percent, 80 percent and 62 percent, respectively of our total
annual consolidated revenue. Our largest strategic partner, POSCO, accounted for 58 percent, 64
percent and 46 percent of total revenues, the U.S. government accounted for 15 percent, 16 percent
and 17 percent of total revenues and Pacific Gas and Electric accounted for 10 percent of total
revenues for the fiscal year ended October 31, 2010. There was no revenue from Pacific Gas and
Electric in 2009 or 2008.
There can be no assurance that we will continue to achieve historical levels of sales of our
products to our largest customers. Even though our customer base is expected to increase and our
revenue streams to diversify, a substantial portion of net revenues could continue to depend on
sales to a limited number of customers. Our agreements with these customers may be cancelled if we
fail to meet certain product specifications or materially breach the agreement, and our customers
may seek to renegotiate the terms of current agreements or renewals. The loss of, or a reduction in
sales to, one or more of our larger customers could have a material adverse affect on our business,
financial condition and results of operations.
See Item 7 Managements Discussion and Analysis of Financial Condition and Results of Operations
and Item 8 Consolidated Financial Statements and Supplementary Data for further information
regarding our revenue and revenue recognition policies.
Backlog refers to the aggregate revenues remaining to be earned at a specified date under contracts
we have entered into. Revenue backlog is as follows:
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Total product sales and service backlog was $154.3 million at October 31, 2010 compared
to $90.7 million as of October 31, 2009. Product order backlog was $87.2 million and $66.4
million as of October 31, 2010 and 2009, respectively, representing 33.5 MW and 43.7 MW as
of October 31, 2010 and October 31, 2009, respectively. Product orders represent 55
percent of our total funded backlog as of October 31, 2010. Backlog for long-term service
agreements was $67.1 million and $24.3 million as of October 31, 2010 and 2009,
respectively. Although backlog reflects business that is considered firm, cancellations or
scope adjustments may occur and will be reflected in our backlog when known. |
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For research and development contracts, we include the total contract value including
any unfunded portion of the total contract value in backlog. Research and development
contract backlog was $9.7 million and $14.2 million as of October 31, 2010 and 2009,
respectively. The unfunded portion of our research and development contracts amounted to
$4.4 million and $10.9 million as of October 31, 2010 and 2009, respectively. Due to the
long-term nature of these contracts, fluctuations from year to year are not an indication
of any future trend. |
As of October 31, 2010 we had contracts for power plants totaling 2.5 MW under PPAs ranging from
five to ten years. Revenue under these agreements is recognized as electricity is produced. This
revenue is not included in backlog described above.
25
Employees
As of October 31, 2010 we had 441 full-time employees, of whom 181 were located at the Torrington,
Connecticut manufacturing plant, and 260 were located at the Danbury, Connecticut facility or
various field offices. None of our employees is represented by a labor union or covered by a
collective bargaining agreement.
Available Information
Our annual report on Form 10-K, quarterly reports on Form 10-Q, current reports on Form 8-K, and
all amendments to those reports will be made available free of charge through the Investor
Relations section of the Companys Internet website (http://www.fuelcellenergy.com) as soon as
practicable after such material is electronically filed with, or furnished to, the Securities and
Exchange Commission (SEC). Material contained on our website is not incorporated by reference in
this report. Our executive offices are located at 3 Great Pasture Road, Danbury, CT 06813.
The public may also read and copy any materials that we file with the SEC at the SECs Public
Reference Room at 100 F Street, NE, Washington, D.C. 20549. The public may obtain information on
the operation of the Public Reference Room by calling the SEC at 1-800-SEC-0330. The SEC also
maintains an Internet website that contains reports and other information regarding issuers that
file electronically with the SEC located at http://www.sec.gov.
26
Executive Officers of the Registrant
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NAME |
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AGE |
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PRINCIPAL OCCUPATION |
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R. Daniel Brdar
President, Chief Executive
Officer and Chairman of the
Board of Directors
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51 |
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Mr. Brdar has been Chairman
of the Board of Directors
since January 2007, Chief
Executive Officer since
January 2006 and President
since August 2005. Mr.
Brdar, previously FuelCell
Energys Executive Vice
President and Chief
Operating Officer, joined
the Company in 2000. Mr.
Brdar held management
positions at General
Electric Power Systems from
1997 to 2000 where he
focused on new product
introduction programs and
was product manager for its
gas turbine technology. Mr.
Brdar was Associate
Director, Office of Power
Systems Product Management
at the U.S. Department of
Energy where he held a
variety of positions from
1988 to 1997 including
directing the research,
development and
demonstration of advanced
power systems including gas
turbines, gasification
systems and fuel cells. Mr.
Brdar received a B.S. in
Engineering from the
University of Pittsburgh in
1981. |
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Christopher R. Bentley Executive
Vice President, Government R&D
Operations, Strategic
Manufacturing Development
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68 |
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Mr. Bentley has been
responsible for Government
Research and Development
Operations and Strategic
Manufacturing Development
since January of 2005. He
joined the Company in 1990
to develop manufacturing and
operations capabilities in
support of the DFC
commercialization
initiative. He served on the
Board of Directors from 1993
to 2004. Prior to joining
the Company, he was Director
of Manufacturing (1985),
Vice-President and General
Manager (1985-1988) and
President (1989) of the
Turbine Airfoils Division of
Chromalloy Gas Turbine
Corporation, a major
manufacturer of gas turbine
hardware. From 1960 to 1985
he was with the General
Electric Company. Mr.
Bentley received a B.S. in
Mechanical Engineering from
Tufts University in 1966. |
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Joseph G. Mahler
Senior Vice President, Chief
Financial Officer, Corporate
Secretary, Treasurer, Corporate
Strategy
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58 |
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Mr. Mahler joined the
Company in October 1998 as
Vice President, Chief
Financial Officer, Corporate
Secretary, and Treasurer.
Mr. Mahlers
responsibilities include
finance, accounting,
corporate governance,
strategy, treasury,
information systems and
human resources. Mr. Mahler
was Vice President-Chief
Financial Officer at
Earthgro, Inc. from 1993 to
1998 and worked at Ernst &
Young in the New York and
Hartford offices from 1974
to 1992. Mr. Mahler was a
partner in the Hartford
offices Entrepreneurial
Services Group. Mr. Mahler
received a B.S. in
Accounting from Boston
College in 1974 and is a
CPA. |
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NAME |
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AGE |
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PRINCIPAL OCCUPATION |
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Anthony F. Rauseo
Senior Vice President, Chief
Operating Officer
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51 |
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Mr. Rauseo was appointed to Chief
Operating Officer in July,
2010. In this position, Mr.
Rauseo has responsibility for
closely integrating the
manufacturing operations with
the supply chain, product
development and quality
initiatives. Mr. Rauseo joined
the Company in 2005 as Vice
President of Engineering and
Chief Engineer. Prior to
joining Fuel Cell Energy, Mr.
Rauseo held a variety of key
management positions in
manufacturing, quality and
engineering including five
years with CiDRA Corporation.
Prior to joining CiDRA, Mr.
Rauseo was with Pratt and
Whitney for 17 years where he
held various leadership
positions in product
development, production and
customer support of aircraft
turbines. Mr. Rauseo received
a Bachelor Science Mechanical
Engineering from Rutgers
University in 1983 and received
a Masters Science Mechanical
Engineering from Rensselaer
Polytechnic Institute in 1987. |
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Arthur A. Bottone
Senior Vice President, Chief
Commercial Officer
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50 |
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Mr. Bottone joined FuelCell
Energy in February 2010 as
Senior Vice President and Chief
Commercial Officer. Mr.
Bottones focus is to
accelerate profitable revenue
growth by capitalizing on
heightened demand by the
worlds industrialized and
emerging nations for clean and
renewable energy. He is also
responsible for developing and
implementing strategies to
further expand the companys
market opportunities and growth
potential. Mr. Bottones
qualifications include 25 years
of experience at Ingersoll Rand
Company, a diversified global
industrial concern. Mr. Bottone
received an undergraduate
degree in Mechanical
Engineering from Georgia
Institute of Technology in
1983, and received a
Certificate of Professional
Development from The Wharton
School, University of
Pennsylvania in 2004. |
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Item 1A. RISK FACTORS
You should carefully consider the following risk factors before making an investment decision. If
any of the following risks actually occur, our business, financial condition, or results of
operations could be materially and adversely affected. In such cases, the trading price of our
common stock could decline, and you may lose all or part of your investment.
We have incurred losses and anticipate continued losses and negative cash flow.
We have been transitioning from a contract research and development company to a commercial
products developer and manufacturer. As such, we have not been profitable since our fiscal year
ended October 31, 1997. We expect to continue to incur net losses and generate negative cash flow
until we can produce sufficient revenues to cover our costs. We may never become profitable. Even
if we do achieve profitability, we may be unable to sustain or increase our profitability in the
future. For the reasons discussed in more detail below, there are substantial uncertainties
associated with our achieving and sustaining profitability. We have, from time to time, sought
financing in the public markets in order to fund operations. Our future ability to obtain such
financing, if required, could be impaired by a variety of factors, including the price of our
common stock, the current global economic crisis and general market conditions.
Our cost reduction strategy may not succeed or may be significantly delayed, which may
result in our inability to offer our products at competitive prices and may adversely affect
our sales.
Our cost reduction strategy is based on the assumption that a significant increase in production
will result in economies of scale. In addition, our cost reduction strategy relies on advancements
in our manufacturing process, global competitive sourcing, engineering design and technology
improvements (including stack life and projected power output). Failure to achieve our cost
reduction targets would have a material adverse effect on our commercialization plans and,
therefore, our business prospects, results of operations and financial condition.
Our products compete with products using other energy sources, and if the prices of the
alternative sources are lower than energy sources used by our products, sales of our
products will be adversely affected. Volatility of electricity prices may impact sales of
our products in the markets in which we compete.
Our DFC Power Plants operate using a variety of hydrocarbon fuels, including natural gas, methanol,
diesel, biogas, coal gas, coal mine methane, and propane. If these fuels are not readily available
or if their prices increase such that electricity produced by our products costs more than
electricity provided by other generation sources, our products would be less economically
attractive to potential customers. In addition, we have no control over the prices of several types
of competitive energy sources such as oil, gas or coal as well as local utility electricity costs.
Significant decreases (or short term increases) in the price of these fuels or grid delivered
prices for electricity could also have a material adverse effect on our business because other
generation sources could be more economically attractive to consumers than our products.
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The reduction or elimination of government subsidies and economic incentives for alternative
energy technologies, including our fuel cell power plants, could reduce demand for our
products, lead to a reduction in our revenues and adversely impact our operating results.
We believe that the near-term growth of alternative energy technologies, including our fuel cells,
relies on the availability and size of government and economic incentives (including, but not
limited to, the U.S. Federal ITC, the incentive programs in South Korea and the state of California
and state RPS programs). Many of these government incentives expire, phase out over time, exhaust
the allocated funding, or require renewal by the applicable authority. In addition, these incentive
programs could be challenged by utility companies, or for other reasons found to be
unconstitutional, and/or could be reduced or discontinued for other reasons. The reduction,
elimination, or expiration of government subsidies and economic incentives may result in the
diminished economic competitiveness of our power plants to our customers and could materially and
adversely affect the growth of alternative energy technologies, including our fuel cells, as well
as our future operating results.
Financial markets worldwide have been impacted by a credit crisis which may have a material
adverse impact on our Company, our customers and our suppliers.
Financial markets have been impacted by a credit crisis worldwide, affecting both debt and equity
markets. This has substantially limited the amount of financing available to all companies,
including companies with substantially greater resources, better credit ratings and more successful
operating histories than ours. It is impossible to predict how long this crisis will last or how it
will be resolved and it may have a materially adverse affect on us for a number of reasons, such
as:
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The long term nature of our sales cycle often requires long lead times
between order booking and product fulfillment. For this, we often
require substantial cash down payments in advance of delivery. Our
growth strategy assumes that financing will be available for our
customers to provide for such down payments and to pay for our
products. The worldwide credit crisis may delay, cancel or restrict
the construction budgets and funds available to our customers that we
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Projects using our products are, in part, financed by equity investors
interested in tax benefits as well as by the commercial and
governmental debt markets. The significant volatility in the U.S. and
international stock markets since 2008, coupled with the failure of
several large financial institutions, has caused significant
uncertainty and resulted in an increase in the return required by
investors in relation to the risk of such projects. This in turn has
increased the cost of capital to the point where new projects or
projects in the early or planning stages may not receive funding or
may have project delays or cancellations. |
If we, or our customers and suppliers, cannot obtain financing under favorable terms during the
current financial crisis or should the financial crisis worsen, our business may be negatively
impacted.
We have signed product sales contracts, long-term service agreements and power purchase
agreements with customers subject to technology and operating risks as well as market
conditions that may affect our operating results.
Revenues from fuel cell product sales contracts are recognized proportionally as costs are incurred
and assigned to a customer contract by comparing the estimated total manufacture and installation
costs for each contract to the total contract value. Prior to fiscal 2010, we have not provided for
a contract loss reserve on product sales contracts as products were in their early stages of
development and market acceptance, and the total costs to produce, install and commission these
units could not be reasonably estimated. As a result of a consistent production rate over the past two fiscal years and
installation and commissioning experience for our major product lines, management now believes that
it has sufficient product cost history to reasonably estimate the total costs of our fuel cell
product sales contracts. Accordingly, effective November 1, 2009, contract loss reserves are
recognized at the time we become aware that estimated total costs are expected to exceed the
contract sales price. Actual results could vary from initial estimates and reserve estimates will
be updated as we gain further manufacturing and operating experience.
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We have contracted under long-term service agreements with certain customers to provide service on
our products over terms ranging from one to 20 years. Under the provisions of these contracts, we
provide services to maintain, monitor, and repair customer power plants to meet minimum operating
levels. Pricing for service contracts is based upon estimates of future costs. While we have
conducted tests to determine the overall life of our products, we have not run our products over
their projected useful life prior to large-scale commercialization. As a result, we cannot be sure
that our products will last to their expected useful life, which could result in warranty claims
and further losses on service contracts.
Under the terms of our Power purchase agreements (PPAs), customers agree to purchase power from
our fuel cell power plants at negotiated rates, generally for periods of five to ten years.
Electricity rates are generally a function of the customers current and future electricity pricing
available from the grid. Revenues are earned and collected under these PPAs as power is produced.
As owner of the power plants, we are responsible for all operating costs necessary to maintain,
monitor and repair the power plants. Under certain agreements, we are also responsible for
procuring fuel, generally natural gas, to run the power plants. Should electricity rates decrease
or operating costs increase from our original estimates, our results of operations could be
negatively impacted. We have qualified for incentive funding for these projects in California under
the states SGIP and from other government programs. Funds are payable upon commercial installation
and demonstration of the plant and may require return of the funds for failure of certain
performance requirements. Revenue related to these incentive funds is recognized ratably over the
performance period. We are not required to produce minimum amounts of power under our PPA
agreements and we have the right to terminate PPA agreements by giving written notice to the
customer, subject to certain exit costs.
We extend product warranties which could affect our operating results.
We warranty our products for a specific period of time against manufacturing or performance
defects. We accrue for warranty costs based on historical warranty claim experience, however actual
future warranty expenses may be greater than weve assumed in our estimates. As a result,
operating results could be negatively impacted should there be product manufacturing or performance
defects in excess of our estimates.
Our products are complex and could contain defects which could reduce sales of those
products or result in claims against us.
We develop complex and evolving products. Despite testing by us, our customers and our suppliers,
issues may be found in existing or new products. This could result in a delay in recognition or
loss of revenues, loss of market share or failure to achieve market acceptance. The occurrence of
defects could also cause us to incur significant warranty, support and repair costs, could divert
the attention of our engineering personnel from our product development efforts, and could harm our
relationships with our customers. The occurrence of these problems could result in the delay or
loss of market acceptance of our products and would likely harm our business. Defects or
performance problems with our products could result in financial or other damages to our customers.
From time to time, we have been involved in disputes regarding product warranty issues. Although we
seek to limit our liability, a product liability claim brought against us, even if unsuccessful,
would likely be time consuming and could be costly to
defend. Our customers could also seek and obtain damages from us for their losses. We have
reserved for potential damages related to performance problems, however actual results may be
different than the assumptions used in our reserve calculations.
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We currently face and will continue to face significant competition.
We compete on the basis of our products reliability, fuel efficiency, environmental considerations
and cost. Technological advances in alternative energy products or improvements in the electric
grid or other sources of power generation, or other fuel cell technologies may negatively affect
the development or sale of some or all of our products or make our products non-competitive or
obsolete prior to commercialization or afterwards. Other companies, some of which have
substantially greater resources than ours, are currently engaged in the development of products and
technologies that are similar to, or may be competitive with, our products and technologies.
Several companies in the U.S. are involved in fuel cell development, although we believe we are the
only domestic company engaged in significant manufacturing and commercialization of carbonate fuel
cells. Emerging fuel cell technologies (and companies developing them) include PEM fuel cells
(Ballard Power Systems, Inc.; United Technologies Corp. or UTC Power; and Plug Power), phosphoric
acid fuel cells (UTC Power and Samsung Everland) and solid oxide fuel cells (Siemens Westinghouse
Electric Company, General Electric, Delphi, Rolls Royce, Bloom Energy, and Acumentrics). Each of
these competitors has the potential to capture market share in our target markets.
There are other potential carbonate fuel cell competitors internationally. In Europe, a company in
Italy, Ansaldo Fuel Cells, is actively engaged in carbonate fuel cell development and is a
potential competitor. Fuji Electric has been involved with both PEM and phosphoric acid fuel cells.
In Korea, Doosan Corporation is engaged in carbonate fuel cell development.
Other than fuel cell developers, we must also compete with such companies as Caterpillar, Cummins,
Wartsilla, MTU, Mitsubishi Heavy Industries and Detroit Diesel, which manufacture more mature
combustion-based equipment, including various engines and turbines, and have well-established
manufacturing, distribution, and operating and cost features. Electrical efficiency of these
products can be competitive with our DFC Power Plants in certain applications. Significant
competition may also come from gas turbine companies like General Electric, Ingersoll Rand, Solar
Turbines and Kawasaki, which have recently made progress in improving fuel efficiency and reducing
pollution in large-size combined cycle natural gas fueled generators. These companies have also
made efforts to extend these advantages to smaller sizes.
We have a large and influential stockholder, which may make it difficult for a third party
to acquire our common stock.
POSCO Power currently owns approximately 10 percent of our outstanding common stock, which could
make it difficult for a third party to acquire our common stock. POSCO Power is also a licensee of
our technology and purchaser of our products. Therefore, it may be in their interests to possess
substantial influence over matters concerning our overall strategy and technological and commercial
development.
We have limited experience manufacturing our products on a commercial basis, which may
adversely affect our planned increases in production capacity and our ability to satisfy
customer requirements.
Our first commercial power plant installation was in 2003 so we have limited experience
manufacturing our products on a commercial basis. Our overall manufacturing process has a
production capacity of 70 MW per year. We expect that we will further increase our manufacturing
capacity based on market
demand. We cannot be sure that we will be able to achieve any planned increases in production
capacity. Also, as we scale up our production capacity, we cannot be sure that unplanned failures
or other technical problems relating to the manufacturing process will not occur.
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Even if we are successful in achieving our planned increases in production capacity, we cannot be
sure that we will do so in time to meet our product commercialization schedule or to satisfy the
requirements of our customers. Additionally, we cannot be sure that we will be able to continue to
develop efficient, low-cost manufacturing capabilities and processes (including automation) that
will enable us to meet our cost goals and profitability projections. Our failure to develop
advanced manufacturing capabilities and processes, or meet our cost goals, could have a material
adverse effect on our business prospects, results of operations and financial condition.
Unanticipated increases or decreases in business growth may result in adverse financial
consequences for us.
If our business grows more quickly than we anticipate, our existing and planned manufacturing
facilities may become inadequate and we may need to seek out new or additional space, at
considerable cost to us. If our business does not grow as quickly as we expect, our existing and
planned manufacturing facilities would, in part, represent excess capacity for which we may not
recover the cost; in that circumstance, our revenues may be inadequate to support our committed
costs and our planned growth, and our gross margins, and business strategy would be adversely
affected.
Our plans are dependent on market acceptance of our products.
Our plans are dependent upon market acceptance of, as well as enhancements to, our products. Fuel
cell systems represent an emerging market, and we cannot be sure that potential customers will
accept fuel cells as a replacement for traditional power sources. As is typical in a rapidly
evolving industry, demand and market acceptance for recently introduced products and services are
subject to a high level of uncertainty and risk. Since the distributed generation market is still
evolving, it is difficult to predict with certainty the size of the market and its growth rate. The
development of a market for our products may be affected by many factors that are out of our
control, including:
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the cost competitiveness of our fuel cell products; |
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the future costs of natural gas and other fuels used by our fuel cell products; |
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customer reluctance to try a new product; |
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perceptions of the safety of our fuel cell products; |
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the market for distributed generation; |
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local permitting and environmental requirements; and |
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the emergence of newer, more competitive technologies and products. |
If a sufficient market fails to develop or develops more slowly than we anticipate, we may be
unable to recover the losses we will have incurred in the development of our products and may never
achieve profitability.
As we continue to commercialize our products, we intend to continue to develop warranties, power
production guarantees and other terms and conditions relating to our products that will be
acceptable to
the marketplace, and continue to develop a service organization that will aid in servicing our
products and obtain self-regulatory certifications, if available, with respect to our products.
Failure to achieve any of these objectives may also slow the development of a sufficient market for
our products and, therefore, have a material adverse effect on our results of operations and
financial condition.
33
We are substantially dependent on a small number of customers and the loss of any one of
these customers could adversely affect our business, financial condition and results of
operations.
We contract with a small number of customers for the sale of our products and for research and
development contracts. For the fiscal years ended October 31, 2010, 2009 and 2008, our top three
customers, POSCO Power, which is a related party and owns approximately 10 percent of the
outstanding common shares of the Company, the U.S. Government (primarily the Department of Energy)
and Pacific Gas and Electric, accounted for 83 percent, 80 percent and 62 percent, respectively of
our total annual consolidated revenue. Our largest strategic partner, POSCO Power, accounted for 58
percent, 64 percent and 46 percent of total revenues, and the U.S. Government accounted for 15
percent, 16 percent and 17 percent of total revenues and Pacific Gas and Electric, accounted for 10
percent of total revenues for the fiscal year ended October 31, 2010 and there was no revenue from
Pacific Gas and Electric for the fiscal years ended 2009 and 2008.
There can be no assurance that we will continue to achieve historical levels of sales of our
products to our largest customers. Even though our customer base is expected to increase and our
revenue streams to diversify, a substantial portion of net revenues could continue to depend on
sales to a limited number of customers. Our agreements with these customers may be cancelled if we
fail to meet certain product specifications or materially breach the agreement, and our customers
may seek to renegotiate the terms of current agreements or renewals. The loss of, or a reduction in
sales to, one or more of our larger customers could have a material adverse effect on our business,
financial condition and results of operations.
Our government research and development contracts are subject to the risk of termination by
the contracting party and we may not realize the full amounts allocated under the contracts
due to the lack of Congressional appropriations.
A portion of our fuel cell revenues have been derived from long-term cooperative agreements and
other contracts with the U.S. Department of Energy, the U.S. Department of Defense, the U.S. Navy,
and other U.S. government agencies. These agreements are important to the continued development of
our technology and our products.
Generally, our U.S. government research and development contracts are subject to the risk of
termination at the convenience of the contracting agency. Furthermore, these contracts,
irrespective of the amounts allocated by the contracting agency, are subject to annual
Congressional appropriations and the results of government or agency sponsored reviews and audits
of our cost reduction projections and efforts. We can only receive funds under these contracts
ultimately made available to us annually by Congress as a result of the appropriations process.
Accordingly, we cannot be sure whether we will receive the full amounts awarded under our
government research and development or other contracts. Failure to receive the full amounts under
any of our government research and development contracts could materially and adversely affect our
business prospects, results of operations and financial condition.
34
A negative government audit could result in an adverse adjustment of our revenue and costs
and could result in civil and criminal penalties.
Government agencies, such as the Defense Contract Audit Agency, routinely audit and investigate
government contractors. These agencies review a contractors performance under its contracts, cost
structure, and compliance with applicable laws, regulations, and standards. If the agencies
determine through these audits or reviews that we improperly allocated costs to specific contracts,
they will not reimburse us for these costs. Therefore, an audit could result in adjustments to our
revenue and costs.
Further, although we have internal controls in place to oversee our government contracts, no
assurance can be given that these controls are sufficient to prevent isolated violations of
applicable laws, regulations and standards. If the agencies determine that we or one of our
subcontractors engaged in improper conduct, we may be subject to civil or criminal penalties and
administrative sanctions, payments, fines, and suspension or prohibition from doing business with
the government, any of which could materially affect our results of operations and financial
condition.
The U.S. government has certain rights relating to our intellectual property, including
restricting or taking title to certain patents.
Many of our U.S. patents relating to our fuel cell technology are the result of government-funded
research and development programs. We own all patents resulting from research funded by our DOE
contracts awarded to date, based on our small business status when each contract was awarded.
Under current regulations, patents resulting from research funded by government agencies other than
the DOE are owned by us, whether or not we are a small business.
Eleven U.S. patents that we own have resulted from government-funded research and are subject to
the risk of exercise of march-in rights by the government. March-in rights refer to the right of
the U.S. government or a government agency to exercise its non-exclusive, royalty-free, irrevocable
worldwide license to any technology developed under contracts funded by the government if the
contractor fails to continue to develop the technology. These march-in rights permit the U.S.
government to take title to these patents and license the patented technology to third parties if
the contractor fails to utilize the patents. In addition, our DOE-funded research and development
agreements also require us to agree that we will not provide to a foreign entity any fuel cell
technology subject to that agreement unless the fuel cell technology will be substantially
manufactured in the U.S. Accordingly, we could lose some or all of the value of these patents.
A failure to qualify as a small business could adversely affect our rights to own future
patents under DOE-funded contracts.
Qualifying as a small business under DOE contracts allows us to own the patents that we develop
under DOE contracts. A small business under applicable government regulations generally consists
of no more than 500 employees averaged over a one year period. If we continue to grow, we will no
longer qualify as a small business and no longer own future patents we develop under future
contracts, grants or cooperative agreements funded by the DOE based on such certification, unless
we obtain a patent waiver from the DOE. Should we not obtain a patent waiver and outright
ownership, we would nevertheless retain exclusive rights to any such patents, so long as we
continue to commercialize the technology covered by the patents. As of October 31, 2010, we had a
total of 441 full-time employees; however, we cannot assure you that we will continue to qualify as
a small business in the future.
35
Our future success and growth is dependent on our market strategy.
We cannot assure you that we will enter into distributor relationships that are consistent with, or
sufficient to support, our commercialization plans, and our growth strategy or that these
relationships will be on terms favorable to us. Even if we enter into these types of relationships,
we cannot assure you that the distributors with which we form relationships will focus adequate
resources on selling our products or will be successful in selling them. Some of these distributor
arrangements have or will require that we grant exclusive distribution rights to companies in
defined territories. These exclusive arrangements could result in our being unable to enter into
other arrangements at a time when the distributor with which we form a relationship is not
successful in selling our products or has reduced its commitment to marketing our products. In
addition, certain distributor arrangements include, and some future distributor arrangements may
also include, the issuance of equity and warrants to purchase our equity, which may have an adverse
affect on our stock price. To the extent we enter into distributor relationships, the failure of
these distributors to assist us with the marketing and distribution of our products may adversely
affect our results of operations and financial condition.
We cannot be sure that our original equipment manufacturers (OEMs) will manufacture or package
products using our Direct FuelCell components. Our success will largely depend upon our ability to
make our products compatible with the power plant products of OEMs and the ability of these OEMs to
sell their products containing our products. In addition, some OEMs may need to redesign or modify
their existing power plant products to fully incorporate our products. Accordingly, any
integration, design, manufacturing or marketing problems encountered by OEMs could adversely affect
the market for our products and, therefore, our business prospects, results of operations and
financial condition.
We depend on third party suppliers for the development and supply of key raw materials and
components for our products.
We use various raw materials and components to construct a fuel cell module, including nickel and
stainless steel which are critical to our manufacturing process. We also rely on third-party
suppliers for the balance-of-plant components in our products. Suppliers must undergo a
qualification process, which takes four to twelve months. We continually evaluate new suppliers and
we are currently qualifying several new suppliers. There are a limited number of suppliers for some
of the key components of products. A suppliers failure to develop and supply components in a
timely manner, supply components that meet our quality, quantity or cost requirements, technical
specifications, or our inability to obtain alternative sources of these components on a timely
basis or on terms acceptable to us could harm our ability to manufacture our Direct FuelCell
products. In addition, to the extent the processes that our suppliers use to manufacture components
are proprietary; we may be unable to obtain comparable components from alternative suppliers.
We do not know when or whether we will secure long-term supply relationships with any of our
suppliers or whether such relationships will be on terms that will allow us to achieve our
objectives. Our business prospects, results of operations and financial condition could be harmed
if we fail to secure long-term relationships with entities that will supply the required components
for our Direct FuelCell products.
We depend on our intellectual property, and our failure to protect that intellectual
property could adversely affect our future growth and success.
Failure to protect our existing intellectual property rights may result in the loss of our
exclusivity or the right to use our technologies. If we do not adequately ensure our freedom to use
certain technology, we may have to pay others for rights to use their intellectual property, pay
damages for infringement or misappropriation, or be enjoined from using such intellectual property.
We rely on patent, trade secret, trademark and copyright law to protect our intellectual property.
As of October 31, 2010, we had 61
current U.S. patents and 66 international patents covering our fuel cell technology. These patents
will expire between 2011 and 2029 and have an average remaining life of approximately 11.2 years.
36
Some of our intellectual property is not covered by any patent or patent application and includes
trade secrets and other know-how that is not able to be patented, particularly as it relates to our
manufacturing processes and engineering design. In addition, some of our intellectual property
includes technologies and processes that may be similar to the patented technologies and processes
of third parties. If we are found to be infringing third-party patents, we do not know whether we
will be able to obtain licenses to use such patents on acceptable terms, if at all. Our patent
position is subject to complex factual and legal issues that may give rise to uncertainty as to the
validity, scope, and enforceability of a particular patent.
We cannot assure you that any of the U.S. or international patents owned by us or other patents
that third parties license to us will not be invalidated, circumvented, challenged, rendered
unenforceable or licensed to others, or any of our pending or future patent applications will be
issued with the breadth of claim coverage sought by us, if issued at all. In addition, effective
patent, trademark, copyright and trade secret protection may be unavailable, limited or not applied
for in certain foreign countries.
We also seek to protect our proprietary intellectual property, including intellectual property that
may not be patented or able to be patented, in part by confidentiality agreements and, if
applicable, inventors rights agreements with our subcontractors, vendors, suppliers, consultants,
strategic partners and employees. We cannot assure you that these agreements will not be breached,
that we will have adequate remedies for any breach or that such persons or institutions will not
assert rights to intellectual property arising out of these relationships. Certain of our
intellectual property have been licensed to us on a non-exclusive basis from third parties that may
also license such intellectual property to others, including our competitors. If our licensors are
found to be infringing third-party patents, we do not know whether we will be able to obtain
licenses to use the intellectual property licensed to us on acceptable terms, if at all.
If necessary or desirable, we may seek extensions of existing licenses or further licenses under
the patents or other intellectual property rights of others. However, we can give no assurances
that we will obtain such extensions or further licenses or that the terms of any offered licenses
will be acceptable to us. The failure to obtain a license from a third party for intellectual
property that we use at present could cause us to incur substantial liabilities, and to suspend the
manufacture or shipment of products or our use of processes requiring the use of that intellectual
property.
While we are not currently engaged in any intellectual property litigation, we could become subject
to lawsuits in which it is alleged that we have infringed the intellectual property rights of
others or commence lawsuits against others who we believe are infringing upon our rights. Our
involvement in intellectual property litigation could result in significant expense to us,
adversely affecting the development of sales of the challenged product or intellectual property and
diverting the efforts of our technical and management personnel, whether or not that litigation is
resolved in our favor.
Our future success will depend on our ability to attract and retain qualified management and
technical personnel.
Our future success is substantially dependent on the continued services and on the performance of
our executive officers and other key management, engineering, scientific, manufacturing and
operating personnel, particularly R. Daniel Brdar, our Chief Executive Officer and Chairman of the
Board of Directors. The loss of the services of any executive officer, including Mr. Brdar, or
other key management, engineering, scientific, manufacturing and operating personnel, could
materially adversely affect our business. Our ability to achieve our development and
commercialization plans will also depend on our ability to attract and retain additional qualified
management and technical personnel. Recruiting personnel for the fuel cell industry is competitive.
We do not know whether we will be able to attract or
retain additional qualified management and technical personnel. Our inability to attract and retain
additional qualified management and technical personnel, or the departure of key employees, could
materially and adversely affect our development and commercialization plans and, therefore, our
business prospects, results of operations and financial condition.
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Our management may be unable to manage rapid growth effectively.
We may rapidly expand our manufacturing capabilities, accelerate the commercialization of our
products and enter a period of rapid growth, which will place a significant strain on our senior
management team and our financial and other resources. Any expansion may expose us to increased
competition, greater overhead, marketing and support costs and other risks associated with the
commercialization of a new product. Our ability to manage rapid growth effectively will require us
to continue to improve our operations, to improve our financial and management information systems
and to train, motivate and manage our employees. Difficulties in effectively managing issues
presented by such a rapid expansion could harm our business prospects, results of operations and
financial condition.
We may be affected by environmental and other governmental regulation.
We are subject to various federal, state and local laws and regulations relating to, among other
things, land use, safe working conditions, handling and disposal of hazardous and potentially
hazardous substances and emissions of pollutants into the atmosphere. In addition, it is possible
that industry-specific laws and regulations will be adopted covering matters such as transmission
scheduling, distribution, and the characteristics and quality of our products, including
installation and servicing. These regulations could limit the growth in the use of carbonate fuel
cell products, decrease the acceptance of fuel cells as a commercial product and increase our costs
and, therefore, the price of our products. Accordingly, compliance with existing or future laws and
regulations could have a material adverse effect on our business prospects, results of operations
and financial condition.
Utility companies could impose customer fees or interconnection requirements on our
customers that could make our products less desirable.
Utility companies commonly charge fees to larger, industrial customers for disconnecting from the
electric grid or for having the capacity to use power from the electric grid for back up purposes.
These fees could increase the cost to our customers of using our Direct FuelCell products and could
make our products less desirable, thereby harming our business prospects, results of operations and
financial condition.
Several states have created and adopted, or are in the process of creating, their own
interconnection regulations covering both technical and financial requirements for interconnection
to utility grids. Depending on the complexities of the requirements, installation of our systems
may become burdened with additional costs that might have a negative impact on our ability to sell
systems. The Institute of Electrical and Electronics Engineers has been working to create an
interconnection standard addressing the technical requirements for distributed generation to
interconnect to utility grids. Many parties are hopeful that this standard will be adopted
nationally to help reduce the barriers to deployment of distributed generation such as fuel cells;
however this standard may not be adopted nationally thereby limiting the commercial prospects and
profitability of our fuel cell systems.
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We could be liable for environmental damages resulting from our research, development or
manufacturing operations.
Our business exposes us to the risk of harmful substances escaping into the environment, resulting
in personal injury or loss of life, damage to or destruction of property, and natural resource
damage. Depending on the nature of the claim, our current insurance policies may not adequately
reimburse us for costs incurred in settling environmental damage claims, and in some instances, we
may not be reimbursed at all. Our business is subject to numerous federal, state, and local laws
and regulations that govern environmental protection and human health and safety. We believe that
our businesses are operating in compliance in all material respects with applicable environmental
laws, however these laws and regulations have changed frequently in the past and it is reasonable
to expect additional and more stringent changes in the future.
Our operations may not comply with future laws and regulations and we may be required to make
significant unanticipated capital and operating expenditures. If we fail to comply with applicable
environmental laws and regulations, governmental authorities may seek to impose fines and penalties
on us or to revoke or deny the issuance or renewal of operating permits and private parties may
seek damages from us. Under those circumstances, we might be required to curtail or cease
operations, conduct site remediation or other corrective action, or pay substantial damage claims.
Our products use inherently dangerous, flammable fuels, operate at high temperatures and use
corrosive carbonate material, each of which could subject our business to product liability
claims.
Our business exposes us to potential product liability claims that are inherent in products that
use hydrogen. Our products utilize fuels such as natural gas and convert these fuels internally to
hydrogen that is used by our products to generate electricity. The fuels we use are combustible and
may be toxic. In addition, our Direct FuelCell products operate at high temperatures and use
corrosive carbonate material, which could expose us to potential liability claims. Although we have
incorporated a robust design and redundant safety features in our power plants and have established
and comprehensive safety, maintenance, and training programs in place, and follow third-party
certification protocols, codes and standards, we cannot guarantee there will not be accidents. Any
accidents involving our products or other hydrogen-using products could materially impede
widespread market acceptance and demand for our products. In addition, we might be held responsible
for damages beyond the scope of our insurance coverage. We also cannot predict whether we will be
able to maintain adequate insurance coverage on acceptable terms.
We are subject to risks inherent in international operations.
Since we market our products both inside and outside the U.S., our success depends in part, on our
ability to secure international customers and our ability to manufacture products that meet foreign
regulatory and commercial requirements in target markets. Sales to customers located outside the
U.S. accounted for 59 percent, 65 percent and 50 percent of our consolidated revenue in fiscal
2010, 2009 and 2008, respectively. Sales to customers in South Korea represent the majority of our
international sales. We have limited experience developing and manufacturing our products to comply
with the commercial and legal requirements of international markets. In addition, we are subject to
tariff regulations and requirements for export licenses, particularly with respect to the export of
some of our technologies. We face numerous challenges in our international expansion, including
unexpected changes in regulatory requirements, potential conflicts or disputes that countries may
have to deal with, fluctuations in currency exchange rates, longer accounts receivable requirements
and collections, difficulties in managing international operations, potentially adverse tax
consequences, restrictions on repatriation of earnings
and the burdens of complying with a wide variety of international laws. Any of these factors could
adversely affect our results of operations and financial condition.
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Our stock price has been and could remain volatile.
The market price for our common stock has been and may continue to be volatile and subject to
extreme price and volume fluctuations in response to market and other factors, including the
following, some of which are beyond our control:
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failure to meet our product development and commercialization milestones; |
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variations in our quarterly operating results from the expectations of securities analysts
or investors; |
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downward revisions in securities analysts estimates or changes in general market conditions; |
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announcements of technological innovations or new products or services by us or our
competitors; |
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announcements by us or our competitors of significant acquisitions, strategic partnerships,
joint ventures or capital commitments; |
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additions or departures of key personnel; |
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investor perception of our industry or our prospects; |
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insider selling or buying; |
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demand for our common stock; and |
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general technological or economic trends. |
In the past, following periods of volatility in the market price of their stock, many companies
have been the subjects of securities class action litigation. If we became involved in securities
class action litigation in the future, it could result in substantial costs and diversion of
managements attention and resources and could harm our stock price, business prospects, results of
operations and financial condition.
Provisions of Delaware and Connecticut law and of our charter and by-laws may make a
takeover more difficult.
Provisions in our certificate of incorporation and by-laws and in Delaware and Connecticut
corporate law may make it difficult and expensive for a third-party to pursue a tender offer,
change in control or takeover attempt that is opposed by our management and board of directors.
Public stockholders who might desire to participate in such a transaction may not have an
opportunity to do so. These anti-takeover provisions could substantially impede the ability of
public stockholders to benefit from a change in control or change in our management and board of
directors.
We depend on relationships with strategic partners, and the terms and enforceability of many
of these relationships are not certain.
We have entered into relationships with strategic partners for design, product development and
distribution of our existing products, and products under development, some of which may not have
been documented by a definitive agreement. The terms and conditions of many of these agreements
allow for
termination by the partners. Termination of any of these agreements could adversely affect our
ability to design, develop and distribute these products to the marketplace. We cannot assure you
that we will be able to successfully negotiate and execute definitive agreements with any of these
partners, and failure to do so may effectively terminate the relevant relationship.
40
Future sales of substantial amounts of our common stock could affect the market price of our
common stock.
Future sales of substantial amounts of our common stock, or securities convertible or exchangeable
into shares of our common stock, into the public market, including shares of our common stock
issued upon exercise of options and warrants, or perceptions that those sales could occur, could
adversely affect the prevailing market price of our common stock and our ability to raise capital
in the future.
The rights of the Series 1 preferred shares and Series B preferred stock could negatively
impact FuelCell.
The terms of the Series 1 preferred shares issued by FuelCell Energy, Ltd. (FCE), our
wholly-owned, indirect subsidiary, provide rights to the holder, Enbridge Inc. (Enbridge), which
could negatively impact us. Quarterly dividends of Cdn.$312,500 accrue on the Series 1 preferred
shares (subject to possible reduction pursuant to the terms of the Series 1 preferred shares). We
have agreed to pay a minimum of Cdn.$500,000 in cash or common stock annually to Enbridge, as long
as Enbridge holds these shares. Interest accrues on cumulative unpaid dividends at an annual rate
of 9 percent, compounded quarterly. All cumulative unpaid dividends originally had to be paid by
December 31, 2010. Using an exchange rate of Cdn.$1.0 to U.S.$1.00 (approximate exchange rate on
December 31, 2010), cumulative unpaid dividends and accrued interest on the Series 1 Preferred
Shares was $12.5 million as of December 31, 2010. The Company and Enbridge have been in
negotiations to modify certain terms of the Series 1 preferred share agreement, and have agreed to
extend the payment deadline to January 31, 2011 to continue these negotiations. Under the existing
terms, FCE Ltd. has the option of meeting this obligation through a cash payment or with
unregistered shares of FuelCell Energy, Inc. common stock. We are a guarantor of FCE Ltds
obligations to Enbridge. In the current negotiations, Enbridge is
seeking terms that, as proposed,
may require payments in excess of those we believe we are obligated to pay. While we intend to
achieve the most favorable outcome in light of our obligations under the Series 1 preferred shares,
we can not presently predict the final terms of any agreement with Enbridge. Subsequent to 2010,
FCE will be required to pay an annual dividend of Cdn.$1.25 million so long as the Series 1
Preferred Shares remain outstanding. The Company has guaranteed FCEs dividend obligations under
the Series 1 preferred shares under a Guarantee Agreement.
We are also required to issue common stock to the holder of the Series 1 preferred shares if and
when the holder exercises its conversion rights. The number of shares of common stock that we may
issue upon conversion could be significant and dilutive to our existing stockholders. For example,
assuming the holder of the Series 1 preferred shares exercises its conversion rights after July 31,
2020 and assuming our common stock price is $1.14 (our common stock closing price on October 31,
2010) and an exchange rate of Cdn.$0.98 to U.S.$1.00 (exchange rate on October 31, 2010) at the
time of conversion, we would be required to issue approximately 22,633,617 shares of our common
stock.
The terms of the Series B preferred stock also provide rights to their holders that could
negatively impact us. Holders of the Series B preferred stock are entitled to receive cumulative
dividends at the rate of $50 per share per year, payable either in cash or in shares of our common
stock. To the extent the dividend is paid in shares, additional issuances could be dilutive to our
existing stockholders and the sale of those shares could have a negative impact on the price of our
common stock. A share of our Series B preferred stock may be converted at any time, at the option
of the holder, into 85.1064 shares of our common stock (which is equivalent to an initial
conversion price of $11.75 per share), plus cash in lieu of fractional
shares. Furthermore, the conversion rate applicable to the Series B preferred stock is subject to
adjustment upon the occurrence of certain events.
41
If we fail to maintain an effective system of internal controls, we may not be able to
accurately report our financial results or prevent fraud, which could harm our brand and
operating results.
Effective internal controls are necessary for us to provide reliable and accurate financial reports
and effectively prevent fraud. We have devoted significant resources and time to comply with the
internal control over financial reporting requirements of the Sarbanes-Oxley Act of 2002. In
addition, Section 404 under the Sarbanes-Oxley Act of 2002 requires that we assess, and that our
auditors attest to, the design and operating effectiveness of our controls over financial
reporting. Our compliance with the annual internal control report requirement for each fiscal year
will depend on the effectiveness of our financial reporting and data systems and controls. Inferior
internal controls could cause investors to lose confidence in our reported financial information,
which could have a negative effect on the trading price of our stock and our access to capital.
Our results of operations could vary as a result of methods, estimates and judgments we use
in applying our accounting policies.
The methods, estimates and judgments we use in applying our accounting policies have a significant
impact on our results of operations (see Critical Accounting Policies and Estimates in Part II,
Item 7 of our Annual Report on Form 10-K for the year ended October 31, 2010. Such methods,
estimates and judgments are, by their nature, subject to substantial risks, uncertainties and
assumptions, and factors may arise over time that could lead us to reevaluate our methods,
estimates and judgments.
As we gain experience in future periods, management will continue to reevaluate its estimates for
contract losses, service agreements, warranty, liquidated damages and inventory reserves. Changes
in those estimates and judgments could significantly affect our results of operations and financial
condition. We may also adopt changes required by the Financial Accounting Standards Board and the
Securities and Exchange Commission.
Health Care Reform Acts
In March 2010, the President of the United States signed the Patient Protection and Affordable Care
Act and the Health Care and Education Reconciliation Act of 2010 (collectively the 2010 Acts).
The 2010 Acts will have a substantial impact on health care providers, insurers, employers and
individuals. The 2010 Acts will impact employers and businesses differently depending on the size
of the organization and the specific impacts on a companys employees. Certain provisions of the
2010 Acts became effective during our open enrollment period (November 1, 2010) while other
provisions of the 2010 Acts will be effective in future years. The 2010 Acts could require, among
other things, changes to our current employee benefit plans, our information technology
infrastructure, and in our administrative and accounting processes. The ultimate extent and cost
of these changes cannot be determined at this time and are being evaluated and updated as related
regulations and interpretations of the 2010 Acts become available.
42
Item 1B. UNRESOLVED STAFF COMMENTS
None.
Item 2. PROPERTIES
The following is a summary of our offices and locations:
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Lease |
|
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|
|
Square |
|
Expiration |
Location |
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Business Use |
|
Footage |
|
Dates |
|
|
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|
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|
|
|
|
Danbury, Connecticut
|
|
Corporate Headquarters, Research and Development,
Sales, Marketing, Purchasing and Administration and
administrative
|
|
|
72,000 |
|
|
Company owned |
|
|
|
|
|
|
|
|
|
Torrington, Connecticut
|
|
Manufacturing and administrative
|
|
|
65,000 |
|
|
December-2015 |
|
|
|
|
|
|
|
|
|
Danbury, Connecticut
|
|
Manufacturing and Operations
|
|
|
38,000 |
|
|
October-2014 |
Item 3. LEGAL PROCEEDINGS
None.
43
PART II
|
|
|
Item 5. MARKET FOR REGISTRANTS COMMON EQUITY, RELATED STOCKHOLDER MATTERS AND ISSUER PURCHASES OF
EQUITY SECURITIES |
FuelCell Common Stock
Our common stock has been publicly traded since June 25, 1992. From September 21, 1994 through
February 25, 1997, it was quoted on the NASDAQ National Market, and from February 26, 1997 through
June 6, 2000 it was traded on the American Stock Exchange. Our common stock trades under the
symbol FCEL on the Nasdaq Global Market. The following table sets forth the high and low sale
prices for our common stock for the fiscal periods indicated as reported by the Nasdaq Global
Market during the indicated quarters.
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|
|
Common Stock |
|
|
|
Price |
|
|
|
High |
|
|
Low |
|
First quarter
(through January 06, 2011) |
|
$ |
2.41 |
|
|
$ |
1.12 |
|
|
|
|
|
|
|
|
|
|
Year Ended October 31, 2010 |
|
|
|
|
|
|
|
|
First Quarter |
|
$ |
4.02 |
|
|
$ |
2.76 |
|
Second Quarter |
|
$ |
3.40 |
|
|
$ |
2.57 |
|
Third Quarter |
|
$ |
2.95 |
|
|
$ |
1.02 |
|
Fourth Quarter |
|
$ |
1.42 |
|
|
$ |
1.04 |
|
|
|
|
|
|
|
|
|
|
Year Ended October 31, 2009 |
|
|
|
|
|
|
|
|
First Quarter |
|
$ |
5.48 |
|
|
$ |
2.25 |
|
Second Quarter |
|
$ |
4.06 |
|
|
$ |
1.98 |
|
Third Quarter |
|
$ |
5.47 |
|
|
$ |
2.76 |
|
Fourth Quarter |
|
$ |
4.61 |
|
|
$ |
3.27 |
|
On January 10, 2011, the closing price of our common stock on the Nasdaq Global Market was $2.01
per share. As of January 10, 2011, there were 590 holders of record of our common stock. This
does not include the number of persons whose stock is in nominee or street name accounts through
brokers.
We have never paid a cash dividend on our common stock and do not anticipate paying any cash
dividends on common stock in the foreseeable future. In addition, the terms of our Series B
preferred shares prohibit the payment of dividends on our common stock unless all dividends on the
Series B preferred stock have been paid in full.
44
Performance Graph
The following graph compares the annual change in the Companys cumulative total stockholder return
on its Common Stock for the five fiscal years ended October 31, 2010 with the cumulative
stockholder total return on the Russell 2000 Index and a peer group consisting of Standard Industry
Classification (SIC) Group Code 369 companies listed on The American Stock Exchange, Nasdaq
Global Market and New York Stock Exchange for that period (Peer Index). It assumes $100 invested
on November 1, 2005 with dividends reinvested.
COMPARISON OF 5-YEAR CUMULATIVE TOTAL RETURN
AMONG FUELCELL ENERGY, INC.
RUSSELL 2000 INDEX AND PEER INDEX
ASSUMES $100 INVESTED ON NOVMEBER 1, 2005
ASSUMES DIVIDEND REINVESTED
FISCAL YEAR ENDED OCTOBER 31, 2010
Series 1 Preferred Shares
We have 1,000,000 Series 1 Class A Cumulative Redeemable Exchangeable Preferred Shares (Series 1
Preferred Shares) issued and outstanding. The Series 1 Preferred Shares were issued by FuelCell
Energy, Ltd. (FCE), one of our wholly-owned subsidiaries. We have guaranteed the obligations of
FCE under the Series 1 Preferred Shares.
A holder of Series 1 Preferred Shares has the right to convert such shares into fully paid and
non-assessable common stock of the Company at the following conversion prices:
|
|
|
Cdn$129.46 per share of our common stock after July 31, 2010 until July 31, 2015; |
|
|
|
|
Cdn$138.71 per share of our common stock after July 31, 2015 until July 31, 2020;
and |
|
|
|
|
at any time after July 31, 2020, at a price equal to 95 percent of the then current
market price (in Cdn.$) of shares of our common stock at the time of conversion. |
45
The foregoing conversion prices are subject to adjustment for certain subsequent events. As
illustrated below, the number of shares of our common stock issuable upon conversion of the Series
1 Preferred Shares after July 31, 2020 may be significantly greater than the number of shares
issuable prior to that time.
The following examples illustrate the number of shares of our common stock that we will be required
to issue to the holder(s) of the Series 1 Preferred Shares if and when the holder(s) exercise their
conversion rights pursuant to the terms of the Series 1 Preferred Shares. The following examples
are based upon Cdn.$25.0 million of Series 1 Preferred Shares outstanding (the amount currently
outstanding) and assume that all accrued dividends have been paid through the time of the
conversion and, in the case of conversions occurring after July 31, 2020, that the exchange rate
for Canadian dollars is Cdn.$0.98 to U.S.$1.00 (exchange rate on October 31, 2010) at the time of
the conversion:
|
|
|
if conversion occurs after July 31, 2010, but prior to July 31, 2015, we would be
required to issue 193,110 shares of our common stock; |
|
|
|
|
if conversion occurs after July 31, 2015, but prior to July 31, 2020, we would be
required to issue 180,232 shares of our common stock; and |
|
|
|
|
if conversion occurs any time after July 31, 2020, assuming our common stock price
is U.S. $1.14 (our common stock closing price on October 31, 2010) at the time of
conversion, we would be required to issue 22,633,617 shares of our common stock. |
Quarterly dividends of Cdn.$312,500 accrue on the Series 1 Preferred Shares (subject to possible
reduction pursuant to the terms of the Series 1 Preferred Shares). We have agreed to pay a minimum
of Cdn.$500,000 in cash or common stock annually to Enbridge Inc. (Enbridge), the sole holder of
the Series 1 Preferred Shares, as long as Enbridge holds these shares. Interest accrues on
cumulative unpaid dividends at an annual rate of 9 percent, compounded quarterly. All cumulative
unpaid dividends originally had to be paid by December 31, 2010. Using an exchange rate of Cdn.$1.0
to U.S.$1.00 (approximate exchange rate on December 31, 2010), cumulative unpaid dividends and
accrued interest on the Series 1 Preferred Shares was $12.5 million as of December 31, 2010. In
December 2010, Enbridge agreed to extend the payment deadline to January 31, 2011. The Company and
Enbridge are in negotiations to modify certain terms of the Series 1 preferred share agreement.
The Series 1 Preferred Shares are redeemable by FCE for Cdn.$25 per share plus all unpaid dividends
and accrued interest. Holders of the Series 1 Preferred Shares do not have any mandatory or
conditional redemption rights.
In the event of the liquidation or dissolution of FCE, the holders of Series 1 Preferred Shares
will be entitled to receive Cdn.$25 per share plus all unpaid dividends and accrued interest before
any amount will be paid or any of FCEs property or assets will be distributed to the holders of
FCEs common stock. After payment to the holders of the Series 1 Preferred Shares of the amounts
payable to them, the holders of the Series 1 Preferred Shares will not be entitled to any other
distribution of FCEs property or assets.
Series B Preferred Shares
We have 250,000 shares of our 5 percent Series B Cumulative Convertible Perpetual Preferred Stock
(Liquidation Preference $1,000) (Series B Preferred Stock) authorized for issuance. At October
31, 2010 and 2009, there were 64,020 and 64,120 shares of Series B Preferred Stock issued and
outstanding.
The shares of our Series B Preferred Stock and the shares of our common stock issuable upon
conversion of the shares of our Series B Preferred Stock are covered by a registration rights
agreement. The following is a summary of certain provisions of our Series B Preferred Stock.
46
Ranking
Shares of Series B Preferred Stock rank with respect to dividend rights and rights upon our
liquidation, winding up or dissolution:
|
|
|
senior to shares of our common stock; |
|
|
|
|
junior to our debt obligations; and |
|
|
|
|
effectively junior to our subsidiaries (i) existing and future liabilities and (ii)
capital stock held by others. |
Dividends
The Series B Preferred Stock pays cumulative annual dividends of $50 per share which are payable
quarterly in arrears on February 15, May 15, August 15 and November 15. Unpaid accumulated
dividends do not bear interest.
The dividend rate is subject to upward adjustment as set forth in the Certificate of Designation if
we fail to pay, or to set apart funds to pay, any quarterly dividend. The dividend rate is also
subject to upward adjustment as set forth in the Registration Rights Agreement entered into with
the Initial Purchasers if we fail to satisfy our registration obligations with respect to the
Series B Preferred Stock (or the underlying common shares) under the Registration Rights Agreement.
No dividends or other distributions may be paid or set apart for payment on our common shares
(other than a dividend payable solely in shares of a like or junior ranking) unless all accumulated
and unpaid Series B Preferred Stock dividends have been paid or funds or shares of common stock
have been set aside for payment of accumulated and unpaid Series B Preferred Stock dividends.
The dividend on the Series B Preferred Stock may be paid in cash; or at the option of the holder,
in shares of our common stock, which will be registered pursuant to a registration statement to
allow for the immediate sale of these common shares in the public market. Dividends of $3.2
million were paid in each of the years ended October 31, 2010 and 2009. There were no cumulative
unpaid dividends at October 31, 2010.
Liquidation
The Series B Preferred Stock stockholders are entitled to receive, in the event that we are
liquidated, dissolved or wound up, whether voluntary or involuntary, $1,000 per share plus all
accumulated and unpaid dividends to the date of that liquidation, dissolution, or winding up
(Liquidation Preference). Until the holders of Series B Preferred Stock receive their Liquidation
Preference in full, no payment will be made on any junior shares, including shares of our common
stock. After the Liquidation Preference is paid in full, holders of the Series B Preferred Stock
will not be entitled to receive any further distribution of our assets. At October 31, 2010 and
2009, the Series B Preferred Stock had a Liquidation Preference of $64.0 million and $64.1 million,
respectively.
Conversion Rights
Each Series B Preferred Stock share may be converted at any time, at the option of the holder, into
85.1064 shares of our common stock (which is equivalent to an initial conversion price of $11.75
per share) plus cash in lieu of fractional shares. The conversion rate is subject to adjustment
upon the occurrence of certain events, as described in the Certificate of Designation, but will not
be adjusted for accumulated and unpaid dividends. If converted, holders of Series B Preferred Stock
do not receive a
cash payment for all accumulated and unpaid dividends; rather, all accumulated and unpaid dividends
are cancelled.
47
We may, at our option, cause shares of Series B Preferred Stock to be automatically converted into
that number of shares of our common stock that are issuable at the then prevailing conversion rate.
We may exercise our conversion right only if the closing price of our common stock exceeds 150
percent of the then prevailing conversion price ($11.75 at October 31, 2010) for 20 trading days
during any consecutive 30 trading day period, as described in the Certificate of Designation.
Redemption
We do not have the option to redeem the shares of Series B Preferred Stock. However, holders of
the Series B Preferred Stock can require us to redeem all or part of their shares at a redemption
price equal to the Liquidation Preference of the shares to be redeemed in the case of a
fundamental change (as described in the Certificate of Designation).
We may, at our option, elect to pay the redemption price in cash or, in shares of our common stock
valued at a discount of 5 percent from the market price of shares of our common stock, or any
combination thereof. Notwithstanding the foregoing, we may only pay such redemption price in
shares of our common stock that are registered under the Securities Act of 1933 and eligible for
immediate sale in the public market by non-affiliates of the Company.
Voting Rights
Holders of Series B Preferred Stock currently have no voting rights; however, holders may receive
certain voting rights, as described in the Certificate of Designation, if (1) dividends on any
shares of Series B Preferred Stock, or any other class or series of stock ranking on a parity with
the Series B Preferred Stock with respect to the payment of dividends, shall be in arrears for
dividend periods, whether or not consecutive, for six calendar quarters or (2) we fail to pay the
redemption price, plus accrued and unpaid dividends, if any, on the redemption date for shares of
Series B Preferred Stock following a fundamental change.
So long as any shares of Series B Preferred Stock remain outstanding, we will not, without the
consent of the holders of at least two-thirds of the shares of Series B Preferred Stock outstanding
at the time (voting separately as a class with all other series of preferred stock, if any, on
parity with our Series B Preferred Stock upon which like voting rights have been conferred and are
exercisable) issue or increase the authorized amount of any class or series of shares ranking
senior to the outstanding shares of the Series B Preferred Stock as to dividends or upon
liquidation. In addition, we will not, subject to certain conditions, amend, alter or repeal
provisions of our certificate of incorporation, including the Certificate of Designation relating
to the Series B Preferred Stock, whether by merger, consolidation or otherwise, so as to adversely
amend, alter or affect any power, preference or special right of the outstanding shares of Series B
Preferred Stock or the holders thereof without the affirmative vote of not less than two-thirds of
the issued and outstanding Series B Preferred Stock shares.
Equity Compensation Plan Information
See Part III, Item 12 for information regarding securities authorized for issuance under our equity
compensation plans.
48
Item 6. SELECTED FINANCIAL DATA
The selected consolidated financial data presented below as of the end of each of the years in the
five-year period ended October 31, 2010 have been derived from our audited consolidated financial
statements together with the notes thereto included elsewhere in this annual report on Form 10-K.
The data set forth below is qualified by reference to, and should be read in conjunction with our
consolidated financial statements and their notes and Managements Discussion and Analysis of
Financial Condition and Results of Operations included elsewhere in this annual report on Form
10-K.
Consolidated Statement of Operations Data:
(Amounts presented in thousands, except for per share amounts)
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|
|
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|
|
|
|
|
|
|
|
|
|
|
|
Years Ended October 31, |
|
|
|
2010 |
|
|
2009 |
|
|
2008 |
|
|
2007 |
|
|
2006 |
|
Revenues: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Product sales and revenues |
|
$ |
59,226 |
|
|
$ |
73,804 |
|
|
$ |
82,748 |
|
|
$ |
32,517 |
|
|
$ |
21,514 |
|
Research and development contracts |
|
|
10,551 |
|
|
|
14,212 |
|
|
|
17,987 |
|
|
|
15,717 |
|
|
|
11,774 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total revenues |
|
|
69,777 |
|
|
|
88,016 |
|
|
|
100,735 |
|
|
|
48,234 |
|
|
|
33,288 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Costs and expenses: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cost of product sales and revenues |
|
|
78,060 |
|
|
|
107,033 |
|
|
|
134,038 |
|
|
|
61,827 |
|
|
|
61,526 |
|
Cost of research and development contracts |
|
|
10,370 |
|
|
|
10,994 |
|
|
|
16,059 |
|
|
|
13,438 |
|
|
|
10,330 |
|
Administrative and selling expenses |
|
|
17,150 |
|
|
|
17,194 |
|
|
|
19,968 |
|
|
|
18,625 |
|
|
|
17,759 |
|
Research and development costs |
|
|
18,562 |
|
|
|
19,160 |
|
|
|
23,471 |
|
|
|
27,489 |
|
|
|
24,714 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total costs and expenses |
|
|
124,142 |
|
|
|
154,381 |
|
|
|
193,536 |
|
|
|
121,379 |
|
|
|
114,329 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss from operations |
|
|
(54,365 |
) |
|
|
(66,365 |
) |
|
|
(92,801 |
) |
|
|
(73,145 |
) |
|
|
(81,041 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Interest expense |
|
|
(127 |
) |
|
|
(265 |
) |
|
|
(100 |
) |
|
|
(84 |
) |
|
|
(103 |
) |
Loss from equity investments |
|
|
(730 |
) |
|
|
(812 |
) |
|
|
(1,867 |
) |
|
|
(1,263 |
) |
|
|
(828 |
) |
Interest and other income, net (1) |
|
|
1,354 |
|
|
|
860 |
|
|
|
3,268 |
|
|
|
7,471 |
|
|
|
5,760 |
|
Redeemable minority interest |
|
|
(2,367 |
) |
|
|
(2,092 |
) |
|
|
(1,857 |
) |
|
|
(1,653 |
) |
|
|
107 |
|
Provision for income tax |
|
|
(91 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss |
|
|
(56,326 |
) |
|
|
(68,674 |
) |
|
|
(93,357 |
) |
|
|
(68,674 |
) |
|
|
(76,105 |
) |
Net loss attributable to noncontrolling interest |
|
|
663 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss attributable to FuelCell Energy, Inc. |
|
|
(55,663 |
) |
|
|
(68,674 |
) |
|
|
(93,357 |
) |
|
|
(68,674 |
) |
|
|
(76,105 |
) |
Preferred stock dividends |
|
|
(3,201 |
) |
|
|
(3,208 |
) |
|
|
(3,208 |
) |
|
|
(3,208 |
) |
|
|
(8,117 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss to common shareholders |
|
$ |
(58,864 |
) |
|
$ |
(71,882 |
) |
|
$ |
(96,565 |
) |
|
$ |
(71,882 |
) |
|
$ |
(84,222 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss to common shareholders |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Basic |
|
$ |
(0.63 |
) |
|
$ |
(0.99 |
) |
|
$ |
(1.41 |
) |
|
$ |
(1.16 |
) |
|
$ |
(1.65 |
) |
Diluted |
|
$ |
(0.63 |
) |
|
$ |
(0.99 |
) |
|
$ |
(1.41 |
) |
|
$ |
(1.16 |
) |
|
$ |
(1.65 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Weighted average shares outstanding |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Basic |
|
|
93,926 |
|
|
|
72,393 |
|
|
|
68,571 |
|
|
|
61,991 |
|
|
|
51,047 |
|
Diluted |
|
|
93,926 |
|
|
|
72,393 |
|
|
|
68,571 |
|
|
|
61,991 |
|
|
|
51,047 |
|
|
|
|
(1) |
|
Includes net license fee income of $34, $42 and $70 for years ended October 31, 2008,
2007 and 2006, respectively that were reported separately in prior years. |
49
Consolidated Balance Sheet Data:
(Amounts presented in thousands, except for per share amounts)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended October 31, |
|
|
|
2010 |
|
|
2009 |
|
|
2008 |
|
|
2007 |
|
|
2006 |
|
Cash and cash equivalents |
|
$ |
20,467 |
|
|
$ |
57,823 |
|
|
$ |
38,043 |
|
|
$ |
92,997 |
|
|
$ |
26,247 |
|
Short-term investments (U.S. treasury securities) |
|
|
25,019 |
|
|
|
7,004 |
|
|
|
30,406 |
|
|
|
60,634 |
|
|
|
81,286 |
|
Working capital |
|
|
48,171 |
|
|
|
77,793 |
|
|
|
59,606 |
|
|
|
158,687 |
|
|
|
104,307 |
|
Total current assets |
|
|
102,209 |
|
|
|
119,679 |
|
|
|
118,020 |
|
|
|
201,005 |
|
|
|
133,709 |
|
Long-term investments (U.S. treasury securities) |
|
|
9,071 |
|
|
|
|
|
|
|
18,434 |
|
|
|
|
|
|
|
13,054 |
|
Total assets |
|
|
150,529 |
|
|
|
162,688 |
|
|
|
185,476 |
|
|
|
253,188 |
|
|
|
206,652 |
|
Total current liabilities |
|
|
54,038 |
|
|
|
41,886 |
|
|
|
58,414 |
|
|
|
42,318 |
|
|
|
29,402 |
|
Total non-current liabilities |
|
|
12,098 |
|
|
|
14,534 |
|
|
|
6,747 |
|
|
|
5,014 |
|
|
|
5,840 |
|
Redeemable minority interest |
|
|
16,849 |
|
|
|
14,976 |
|
|
|
13,307 |
|
|
|
11,884 |
|
|
|
10,665 |
|
Redeemable preferred stock |
|
|
59,857 |
|
|
|
59,950 |
|
|
|
59,950 |
|
|
|
59,950 |
|
|
|
59,950 |
|
Total equity |
|
|
7,687 |
|
|
|
31,342 |
|
|
|
47,058 |
|
|
|
134,022 |
|
|
|
100,795 |
|
Book value per share (1) |
|
$ |
0.07 |
|
|
$ |
0.37 |
|
|
$ |
0.68 |
|
|
$ |
1.97 |
|
|
$ |
1.90 |
|
|
|
|
(1) |
|
Calculated as total equity divided by common shares issued and outstanding as of the balance
sheet date. |
50
|
|
|
Item 7. MANAGEMENTS DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND RESULTS OF OPERATIONS |
The following discussion should be read in conjunction with information included in Item 8 of this
report. Unless otherwise indicated, the terms Company, FuelCell Energy, we, us, and our
refer to FuelCell Energy Inc. and its subsidiaries. All tabular dollar amounts are in thousands.
In addition to historical information, this discussion and analysis contains forward-looking
statements. All forward-looking statements are subject to risks and uncertainties that could cause
actual results to differ materially from those projected. Factors that could cause such a
difference include, without limitation, the risk that commercial field trials of our products will
not occur when anticipated, general risks associated with product development and manufacturing,
changes in the utility regulatory environment, potential volatility of energy prices, rapid
technological change, competition, market acceptance of our products and our ability to achieve our
sales plans and cost reduction targets, as well as other risks set forth in our filings with the
Securities and Exchange Commission including those set forth under Item 1A Risk Factors in this
report.
Overview and Recent Developments
Overview
We are a world leader in the development and production of stationary fuel cells for commercial,
industrial, government and utility customers. Our ultra-clean, high efficiency Direct
FuelCell® (DFC®) power plants are generating power at over 50 locations worldwide. Our
products have generated over 650 million kWh of power using a variety of fuels including renewable
wastewater gas, food and beverage waste, natural gas and other hydrocarbon fuels.
Our vision is to provide ultra-clean, highly efficient, reliable distributed generation baseload
power at a cost per kilowatt hour that is less than the cost of grid-delivered electricity. On an
un-subsidized basis, our power plants provide electricity that is priced competitively to
grid-delivered electricity in certain high cost regions of the United States.
Our Company was founded in Connecticut in 1969 and reincorporated in Delaware in 1999. Our core
fuel cell products (Direct FuelCell® or DFC® Power Plants) offer highly
efficient stationary power generation for customers. In addition to our commercial products, we
continue to develop our carbonate fuel cells, planar solid oxide fuel cell (SOFC) technology and
other fuel cell technology with our own and government research and development funds.
Our proprietary carbonate DFC Power Plants electrochemically (without combustion) produce
electricity directly from readily available hydrocarbon fuels such as natural gas and biogas in a
highly efficient process. The primary byproducts of the fuel cell process are heat and water. Due
to the lack of combustion, our fuel cells emit virtually zero pollutants such as NOx, SOx or
particulate matter.
Our fuel cells operate 24 hours per day seven days per week providing reliable power to both
on-site customers and grid-support applications. Our DFC Power Plants can be part of a total
on-site power generation solution with our high efficiency products providing base load power. Our
power plants can also work in conjunction with intermittent power, such as solar or wind, or less
efficient combustion-based equipment that provide peaking and load following energy. Our products
are also well suited for meeting the needs of utility grid-support applications.
Higher fuel efficiency results in lower emissions of carbon dioxide (CO2), a major greenhouse
gas, and also results in less fuel needed per kWh of electricity generated and Btu of heat
produced. The high efficiency of the DFC Power Plant results in significantly less CO2 per unit of
power production compared to the average U.S. fossil fuel power plant. Greater efficiency reduces
customers exposure to volatile fuel costs, minimizes operating costs, and provides maximum electrical output from a
finite fuel source. DFC Power Plants achieve electrical efficiencies of 47 percent to 60 percent
or higher depending on configuration, location, and application, and up to 90 percent total
efficiency in combined heat and power applications.
51
A fuel cell power plant includes the fuel cell stack module that produces the electricity, and
balance-of-plant (BOP). The mechanical balance-of-plant processes the incoming fuel such as
natural gas or renewable biogas and includes various fuel handling and processing equipment such as
pipes and blowers. The electrical balance-of-plant processes the power generated for use by the
customer and includes electrical interface equipment such as inverters.
Our fuel cells operate on a variety of hydrocarbon fuels, including natural gas, renewable biogas,
propane, methanol, coal gas, and coal mine methane.
Compared to other power generation technologies, our products offer significant advantages
including:
|
|
|
Near-zero pollutants; |
|
|
|
|
High efficiency; |
|
|
|
|
Ability to site units locally as distributed power generation; |
|
|
|
|
Potentially lower cost power generation; |
|
|
|
|
Byproduct heat ideal for cogeneration applications; |
|
|
|
|
High efficiency and cogeneration reduce carbon emissions |
|
|
|
|
Reliable around-the-clock base load power; |
|
|
|
|
Quiet operation; and |
|
|
|
|
Fuel flexibility. |
Typical customers for our products include universities, manufacturers, mission critical
institutions such as correction facilities and government installations, hotels, natural gas
letdown stations and customers who can use renewable biogas for fuel such as municipal water
treatment facilities, breweries, and food processors. Our MW-class products are also used to
supplement the grid for utility customers. With increasing demand for renewable and ultra-clean
power options and increased volatility in electric markets, our products offer our customers
greater control over power generation economics, reliability, and emissions.
Our DFC Power Plants are protected by 61 U.S. and 66 international patents. We currently have 30
U.S. and 130 international patents under application.
Recent Developments
Registered Direct Offering
On January 10, 2011 we announced entry into a definitive agreement with an institutional investor
to sell an aggregate of 10,160,428 units at a negotiated price of $1.87 per unit, with each unit
consisting of (i) one share of its common stock, par value $0.0001 per share (Common Stock) and
(ii) one warrant to purchase 1.0 share of Common Stock, in a registered direct offering for gross
proceeds of $19.0 million. The net proceeds from the sale of the units, after deducting the
placement agent fees and other estimated offering expenses, will be approximately $17.8 million.
We intend to use the proceeds from this offering for product development, project financing,
expansion of manufacturing capacity, and general corporate purposes.
The warrants have an exercise price of $2.29 per share and are exercisable beginning on the date
that is six months and one day after the closing date and will expire twenty one months after
issuance. Additionally, FuelCell Energy will obtain the right, subject to certain conditions, to
require the investor
to purchase up to 10.0 million additional shares approximately nine months after the initial
closing date of the transaction. The sale price for the additional shares will be based on a fixed
ten percent discount to a volume weighted average price (VWAP) measurement at the time FuelCell
Energy exercises the option. FuelCell Energy cannot require the investor to purchase more than $20
million of additional shares.
52
The offering closed on January 13, 2011. Lazard Capital Markets LLC served as the sole placement
agent for the offering.
Public Offering
In July 2010 we completed an underwritten public offering of 27,600,000 shares of common stock at a
price to the public of $1.25 per share. Net proceeds to the Company from the offering, after
deducting the underwriters discounts and commissions and offering expenses, were approximately
$32.1 million.
Commercial Products
California: Clean energy deployment remains a focus in California with 15.2 MW of orders received
during fiscal 2010. The State and its Public Utilities Commission are driving clean energy
deployment to reduce greenhouse gases and pollution while encouraging the utilization of
distributed generation. Fiscal 2010 California orders are for use at wasterwater treatment
facilities, universities, municipal pump stations and animal farms and will utilize a variety of
fuels, including renewable biogas, directed biogas, animal waste, and natural gas. The financing
used for these projects included publicly issued bonds, equity and debt investments by investors
and commercial bank financing.
South Korea: In March 2010, the National Assembly of the Republic of Korea passed a Renewable
Portfolio Standard (RPS) requiring 4 percent clean energy generation by 2015 and 10 percent by
2022. The program, which will become effective in 2012, will mandate 350 MW of additional
renewable energy per year through 2016, and 700 megawatts per year through 2022. Carrying forward
the policy introduced in 2006 under Koreas feed-in tariff program, the government has elected to
designate fuel cells operating on natural gas and biogas as New and Renewable Energy, fully
qualifying under the new program.
In response to the new South Korean RPS, POSCO Power began construction of a 100 MW fuel cell stack
assembly plant in South Korea in April 2010 with production expected to begin in early 2011. For
this facility, POSCO Power procured fuel cell stack module assembly and conditioning equipment
through FCE which will be used to assemble and condition fuel cell stacks in South Korea using fuel
cell components supplied by FuelCell Energy.
In 2010, POSCO Power also ordered a 300 kilowatt DFC 300MA fuel cell power plant to develop market
applications that target grid support combined with the ability to provide emergency power for
installations requiring an uninterrupted supply of power. In the event of temporary interruption of
power from the transmission grid, the fuel cell power plant would then switch and provide power to
the installation. The South Korean Government is providing financial support for the purchase of
this fuel cell power plant and associated development activities.
We have also partnered with POSCO Power to expand the market for fuel cells in South Korea through
development of a small-scale Direct FuelCell power plant targeted at the commercial/apartment
building market. POSCO Power will fund the development under a joint development agreement
announced subsequent to the fiscal year ended October 31, 2010. The $5.8 million program will be
funded in stages as performance milestones are reached.
Connecticut: The Company continues active discussions with private and government financing sources
for the 43.5 MW of fuel cell projects selected and approved by the Connecticut Department of
Utility Control. The Company also received 0.9 MW of orders in Connecticut during fiscal 2010.
53
Government Research and Development Contracts
Advanced Hydrogen Programs:
|
|
|
A DFC300-H2 power plant has been installed at a wastewater treatment facility in
Los Angeles, California to supply 1) hydrogen for use in fuel cell vehicle refueling, 2)
clean electricity, and 3) high quality heat for the wastewater treatment process. The
plant began operating on natural gas during the fourth quarter of 2010 and is expected to
be operational on renewable biogas by early 2011. The demonstration is being performed
under sub-contract to Air Products with the majority of funding provided by the U.S.
Department of Energy (DOE). |
|
|
|
|
The Company was awarded approximately $2.8 million during the fourth quarter of
2010 by the DOE to demonstrate the hydrogen production capacity of a DFC power plant for
use by the metal processing industry. A DFC300-H2 will be configured to generate three
value streams including: 1) hydrogen for use in a heat treating process, 2) clean
electricity, and 3) high quality heat. Over 600 companies operate in the metal processing
industry in the USA, representing a significant potential market. |
Hydrogen Compression: The Company was awarded approximately $2.0 million during the fourth quarter
of 2010 by the DOE to further develop and demonstrate a highly efficient and reliable method for
compressing hydrogen utilizing its solid-state Electrochemical Hydrogen Compressor (EHC)
technology. The EHC technology can be utilized to compress hydrogen for storage, transport and
subsequent use for vehicle refueling or other industrial applications.
Solid Oxide Fuel Cell Development: The Company continues to partner with Versa Power Systems Inc.
(Versa), for the development of a Large Scale Coal-Based Solid Oxide Fuel Cell under the U.S.
Department of Energy Solid State Energy Conversion Alliance (SECA) Program. The FuelCell
Energy/Versa team met cost and performance objectives for a minimum 25 kW fuel cell stack in Phase
II of the program. The full scale advanced fuel cell system to be demonstrated in Phase III is
expected to incorporate an SOFC module with an output of up to 250 kW to efficiently convert the
energy contained in coal to ultra-clean grid electrical power. We have submitted a bid for
approximately $34 million to the DOE for Phase III and expect a decision in early 2011.
Series 1 Preferred Share Obligation
As previously disclosed, our wholly owned subsidiary (FCE Ltd) had a $12.5 million obligation
originally due to Enbridge on December 31, 2010. The Company and Enbridge have been in negotiations
to modify certain terms of the Series 1 preferred share agreement, and have agreed to extend the
payment deadline to January 31, 2011 to continue these negotiations. Under the existing terms, FCE
Ltd. has the option of meeting this obligation through a cash payment or with unregistered shares
of FuelCell Energy, Inc. common stock. The Company is a guarantor of FCE Ltds obligations to
Enbridge. In the current negotiations, Enbridge is seeking terms that, as proposed, may require
payments in excess of those we believe we are obligated to pay. While we intend to achieve the
most favorable outcome in light of our obligations under the Series 1 preferred shares, it can not
presently predict the final terms of any agreement with Enbridge.
This obligation relates to dividends accrued on the series 1 preferred stock acquired in the 2003
acquisition of Global Thermoelectric, Inc (GTI). This obligation has been reported in temporary
equity on the balance sheet as redeemable preferred stock of subsidiary. We acquired Global
Thermoelectric
due to their expertise in solid oxide fuel cell technology. At the time of the acquisition,
Enbridge owned preferred shares in GTI. Refer also to Note 11 of the Consolidated Financial
Statements.
54
Revolving Credit Facility
In January 2011, the Company entered into a $5.0 million revolving credit facility with JPMorgan
Chase Bank, N.A. and the Export-Import Bank of the United States. The credit facility is to be
used for working capital to finance the manufacture and production and subsequent export sale of
the Companys products or services. The agreement has a one year term with renewal provisions. The
outstanding principal balance of the facility will bear interest, at the option of the Company of
either the one-month LIBOR plus 1.5 percent or the prime rate of JP Morgan Chase. The facility is
secured by certain working capital assets and general intangibles, up to the amount of the
outstanding facility balance.
Results of Operations
Management evaluates the results of operations and cash flows using a variety of key performance
indicators including revenues compared to prior periods and internal forecasts, costs of our
products and results of our cost-out initiatives, and operating cash use. These are discussed
throughout the Results of Operations and Liquidity and Capital Resources sections.
Comparison of the Years Ended October 31, 2010 and October 31, 2009
Revenues and Costs of revenues
Revenues, cost of revenues, gross margins and cost ratios for the years ended October 31, 2010 and
2009 were as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year Ended |
|
|
Year Ended |
|
|
|
|
|
|
October 31, 2010 |
|
|
October 31, 2009 |
|
|
|
|
|
|
|
|
|
|
Percent of |
|
|
|
|
|
|
Percent of |
|
|
Percentage |
|
|
|
Revenues |
|
|
Revenues |
|
|
Revenues |
|
|
Revenues |
|
|
change |
|
Revenues: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Product sales and revenues |
|
$ |
59,226 |
|
|
|
85 |
% |
|
$ |
73,804 |
|
|
|
84 |
% |
|
|
(20 |
)% |
Research and development contracts |
|
|
10,551 |
|
|
|
15 |
% |
|
|
14,212 |
|
|
|
16 |
% |
|
|
(26 |
)% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total revenues |
|
$ |
69,777 |
|
|
|
100 |
% |
|
$ |
88,016 |
|
|
|
100 |
% |
|
|
(21 |
)% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Costs and expenses: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cost of product sales and revenues |
|
$ |
78,060 |
|
|
|
88 |
% |
|
$ |
107,033 |
|
|
|
91 |
% |
|
|
(27 |
)% |
Cost of research and development contracts |
|
|
10,370 |
|
|
|
12 |
% |
|
|
10,994 |
|
|
|
9 |
% |
|
|
(6 |
)% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total costs and expenses |
|
$ |
88,430 |
|
|
|
100 |
% |
|
$ |
118,027 |
|
|
|
100 |
% |
|
|
(25 |
)% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Gross Margin: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cost of product sales and revenues |
|
$ |
(18,834 |
) |
|
|
101 |
% |
|
$ |
(33,229 |
) |
|
|
111 |
% |
|
|
(43 |
)% |
Cost of research and development contracts |
|
|
181 |
|
|
|
(1 |
)% |
|
|
3,218 |
|
|
|
(11 |
)% |
|
|
(94 |
)% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total gross margin |
|
$ |
(18,653 |
) |
|
|
100 |
% |
|
$ |
(30,011 |
) |
|
|
100 |
% |
|
|
(38 |
)% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Product Sales Cost-to-revenue ratio |
|
|
1.32 |
|
|
|
|
|
|
|
1.45 |
|
|
|
|
|
|
|
|
|
Total revenues for the year ended October 31, 2010 decreased by $18.2 million, or 21 percent, to
$69.8 million from $88.0 million during the same period last year. Total cost of revenues for the
year ended October 31, 2010 decreased by $29.6 million, or 25 percent, to $88.4 million from $118.0
million during the same period last year.
55
We contract with a small number of customers for the sale of our products and for research and
development contracts. For the fiscal years ended October 31, 2010, 2009 and 2008, our top three
customers, POSCO, which is a related party and owns approximately 10 percent of the outstanding
common shares of the Company, the U.S. government (primarily the Department of Energy) and Pacific
Gas and Electric, accounted for 83 percent, 80 percent and 63 percent, respectively, of our total
annual consolidated revenue. Our largest strategic partner, POSCO, accounted for 58 percent, 64
percent and 46 percent, respectively, of total revenues, the U.S. government accounted for 15
percent, 16 percent and 17 percent, respectively, of total revenues and Pacific Gas and Electric
accounted for 10 percent of total revenues for the fiscal year ended October 31, 2010 and there was
no revenue from Pacific Gas and Electric in 2009 or 2008.
There can be no assurance that we will continue to achieve historical levels of sales of our
products to our largest customers. Even though our customer base is expected to increase and our
revenue streams to diversify, a substantial portion of net revenues could continue to depend on
sales to a limited number of customers. Our agreements with these customers may be cancelled if we
fail to meet certain product specifications or materially breach the agreement, and our customers
may seek to renegotiate the terms of current agreements or renewals. The loss of, or a reduction in
sales to, one or more of our larger customers could have a material adverse affect on our business,
financial condition and results of operations.
Product sales and revenues
We have historically sold our fuel cell products below cost while the market develops and product
costs are reduced. We have been engaged in a formal commercial cost-out program since 2003 to
reduce the total life cycle costs of our power plants and have made significant progress primarily
through value engineering our products, manufacturing process improvements, higher production
levels, technology improvements and global sourcing. During fiscal 2009, we began production of our
newest MW-class power plants. The new design incorporates new stacks with outputs of 350 kW each
compared to 300 kW previously, along with lower component and raw material costs derived from
process improvements, volume manufacturing and global sourcing. As a result, we have seen
significant improvement in our manufactured product margins during fiscal 2010. The overall
product cost-to-revenue ratio (including warranty expenses, liquidated damages, costs to service
power plants for customers with LTSAs, PPA operating costs and LCM adjustments) improved to 1.32 in
fiscal 2010 from 1.45 in fiscal 2009.
Product sales and revenues decreased $14.6 million to $59.2 million for fiscal 2010, compared to
$73.8 million for fiscal 2009. Lower product revenue resulted from the transition in product sales
mix to POSCO from complete power plants in fiscal 2009 to a larger proportion in fiscal 2010 being
only for the stack module part of the power plant. Partially offsetting this decline was higher
revenue from LTSAs due to sales of service agreements on power plant installations in South Korea.
Revenue in fiscal 2010 included $46.5 million of product sales (complete power plants, modules and
components), $3.6 million related to the sale of stack module assembly and conditioning equipment
to POSCO and for site engineering and construction work for projects where we are responsible for
complete power plant system installation, $6.9 million related to service agreements and component
sales and $2.2 million related to PPAs.
Cost of product sales and revenues decreased to $78.1 million for fiscal 2010, compared to $107.0
million during 2009. This decrease is due to the transition of production for POSCO from complete
power plants to only the stack module part of the power plant, production of lower cost products
and the impact from higher costs in 2009 due to delays in commissioning and final acceptance
testing on the first multi-megawatt products installed in South Korea. Although we did continue to
incur some post installation issues in fiscal 2010 in South Korea, they were significantly less
than in fiscal 2009.
Cost of product sales and revenues includes costs to manufacture and ship our power plants and
power plant components to customers, site engineering and construction costs where we are
responsible for power plant system installation, costs for stack module assembly and conditioning
equipment sold to
POSCO, warranty expense, liquidated damages and costs to service power plants for customers with
long-term service agreements (including maintenance and stack replacement costs incurred during the
period), PPA operating costs and LCM adjustments.
56
Service agreements and aftermarket costs, net of revenues, totaled $13.9 million for the fiscal
year ended October 31, 2010 compared to $14.4 million in the same period of the prior year. The
decrease in net service agreement and aftermarket costs is primarily due to lower stack replacement
and routine maintenance costs.
Research and development contracts
Research and development contracts revenue is derived primarily (greater than 90 percent) from the
DOE and other governmental agencies. Research and development contracts revenue and related costs
for the fiscal years ended October 31, 2010 and 2009 were as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended |
|
|
|
|
|
|
October 31, |
|
|
Percentage |
|
|
|
2010 |
|
|
2009 |
|
|
change |
|
|
|
Research and development contracts |
|
$ |
10,551 |
|
|
$ |
14,212 |
|
|
|
(26 |
)% |
Cost of research and development contracts |
|
|
10,370 |
|
|
|
10,994 |
|
|
|
(6 |
)% |
|
|
|
|
|
|
|
|
|
|
|
Gross margin |
|
$ |
181 |
|
|
$ |
3,218 |
|
|
|
(94 |
)% |
|
|
|
|
|
|
|
|
|
|
|
Research and development contracts revenue decreased $3.7 million to $10.5 million for fiscal 2010,
compared to $14.2 million for 2009. Cost of research and development contracts decreased $0.6
million to $10.4 million during fiscal 2010, compared to $11.0 million for 2009. Margin from
research and development contracts for 2010 was $0.2 million or 2 percent, compared to $3.2 million
or 23 percent in 2009. The decline in revenue was primarily due to lower activity on the SECA
program.
Administrative and selling expenses
Administrative and selling expenses remained unchanged at $17.2 million during fiscal 2010,
compared to 2009.
Research and development expenses
Research and development expenses decreased $0.6 million to $18.6 million during fiscal 2010,
compared to $19.2 million in 2009. The decrease is related to the cash management plan implemented
in fiscal 2009 and increased support by the Companys engineers on non-research and development
activities.
Loss from operations
Loss from operations for the fiscal year ended October 31, 2010 was $54.4 million compared to a
loss of $66.4 million in 2009. The improvement in net loss from operations was due to the $11.4
million net improvement in gross margin on product sales and research and development contracts and
lower research and development expenses.
Loss from equity investments
Our ownership interest in Versa Power Systems, Inc. (Versa) at October 31, 2010 was 39 percent,
unchanged from 2009. We account for the investment under the equity method of accounting. Our share
of equity losses from Versa decreased $0.1 million to $0.7 million in fiscal 2010 compared to $0.8
million in 2009. This decrease was due to lower cost share requirements on research and development
activity being performed by Versa.
57
Interest and other income, net
Interest and other income, net, increased to $1.4 million for fiscal 2010 compared to $0.9 million
for 2009. The increase is due to license fee income on the POSCO technology transfer agreements.
Provision for income taxes
We have not paid federal or state income taxes in several years due to our history of net operating
losses, although we have paid foreign taxes in South Korea. In fiscal 2010, our provision for
income taxes was $0.1 million, which related to South Korean tax obligations. During 2009, we
began manufacturing products that are gross margin profitable on a per unit basis; however, we
cannot estimate when production volumes will be sufficient to generate taxable income. Accordingly,
no tax benefit has been recognized related to current or prior year losses and other deferred tax
assets as significant uncertainty exists surrounding the recoverability of these deferred tax
assets. Approximately $4.2 million of our valuation allowance would reduce additional paid in
capital upon subsequent recognition of any related tax benefits.
As of October 31, 2010, we had $541 million of federal NOL carryforwards that expire in the years
2020 through 2030 and $343 million in state NOL carryforwards that expire in the years 2011 through
2030. Additionally, we had $8.7 million of state tax credits available, of which $1.0 million
expires in 2018. The remaining credits do not expire.
Net loss attributable to noncontrolling interest
The net loss attributed to the noncontrolling interest for 2010 was $0.7 million. During the year,
we adopted new guidance on the accounting for noncontrolling interest (formerly minority
interest). See Note 1 to the Consolidated Financial Statements for further details.
58
Comparison of the Years Ended October 31, 2009 and October 31, 2008
Revenues and Costs of revenues
Revenue, cost of revenues, gross margins and cost ratios for the years ended October 31, 2009 and
2008 were as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended |
|
|
Years Ended |
|
|
|
|
|
|
October 31, 2009 |
|
|
October 31, 2008 |
|
|
Percentage |
|
|
|
|
|
|
|
Percent of |
|
|
|
|
|
|
Percent of |
|
|
change in |
|
|
|
Revenues |
|
|
Revenues |
|
|
Revenues |
|
|
Revenues |
|
|
Revenue |
|
Revenues: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Product sales and revenues |
|
$ |
73,804 |
|
|
|
84 |
% |
|
$ |
82,748 |
|
|
|
82 |
% |
|
|
(11 |
)% |
Research and development contracts |
|
|
14,212 |
|
|
|
16 |
% |
|
|
17,987 |
|
|
|
18 |
% |
|
|
(21 |
)% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total revenues |
|
$ |
88,016 |
|
|
|
100 |
% |
|
$ |
100,735 |
|
|
|
100 |
% |
|
|
(13 |
)% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Costs and expenses: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cost of product sales and revenues |
|
$ |
107,033 |
|
|
|
91 |
% |
|
$ |
134,038 |
|
|
|
89 |
% |
|
|
(20 |
)% |
Cost of research and development contracts |
|
|
10,994 |
|
|
|
9 |
% |
|
|
16,059 |
|
|
|
11 |
% |
|
|
(32 |
)% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total costs and expenses |
|
$ |
118,027 |
|
|
|
100 |
% |
|
$ |
150,097 |
|
|
|
100 |
% |
|
|
(21 |
)% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Gross Margin: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cost of product sales and revenues |
|
$ |
(33,229 |
) |
|
|
111 |
% |
|
$ |
(51,290 |
) |
|
|
104 |
% |
|
|
(35 |
)% |
Cost of research and development contracts |
|
|
3,218 |
|
|
|
(11 |
)% |
|
|
1,928 |
|
|
|
(4 |
)% |
|
|
67 |
% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total gross margin |
|
$ |
(30,011 |
) |
|
|
100 |
% |
|
$ |
(49,362 |
) |
|
|
100 |
% |
|
|
(39 |
)% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Product Sales Cost-to-revenue ratio |
|
|
1.45 |
|
|
|
|
|
|
|
1.62 |
|
|
|
|
|
|
|
|
|
Total revenues for the year ended October 31, 2009 decreased by $12.7 million, or 13 percent, to
$88.0 million from $100.7 million during the same period last year. Total cost of revenues for the
year ended October 31, 2009 decreased by $32.1 million, or 21 percent, to $118.0 million from
$150.1 million during the same period last year.
We contract with a small number of customers for the sale of our products and for research and
development contracts. For the fiscal years ended October 31, 2009 and 2008, our top two customers,
POSCO and the DOE, accounted for 80 percent and 62 percent, respectively, of our total annual
consolidated revenue. POSCO, accounted for 64 percent and 46 percent, respectively, of total
revenues, and the DOE and other governmental agencies accounted for 16 percent and 17 percent,
respectively, of total revenues for the fiscal years ended October 31, 2009 and 2008.
Product sales and revenues
Product sales and revenues decreased $8.9 million to $73.8 million for fiscal 2009, compared to
$82.7 million for fiscal 2008. Reduced site engineering and construction work of $6.7 million and
lower component sales of $1.5 million drove the decrease. Revenue in fiscal 2009 included $63.2
million of power plant sales compared to $64.3 million last year, $2.0 million related to site
engineering and construction work for projects where we are responsible for complete power plant
system installation compared to $8.7 million last year, $6.0 million related to service agreements
and component sales compared to $6.8 million last year and $2.6 million of revenue related to PPAs
compared to $2.9 million last year.
59
Cost of product sales and revenues decreased to $107.0 million for fiscal 2009, compared to $134.0
million during 2008. The cost-to-revenue ratio also decreased to 1.45-to-1 during fiscal 2009,
compared to 1.62-to-1 during the same period a year ago. The cost-to-revenue ratio was favorably
impacted in fiscal 2009 by the shift to lower cost MW-class products and lower unit costs across
all product lines. In the
second half of the fiscal year we experienced delays in commissioning and final acceptance testing
on the first multi-MW products installed in South Korea. This resulted in higher costs which
negatively impacted the cost-to-revenue ratio.
Cost of product sales and revenues includes costs to manufacture and ship our power plants and
power plant components to customers, site engineering and construction costs where we are
responsible for power plant system installation, warranty expense, liquidated damages and costs to
service power plants for customers with long-term service agreements (including maintenance and
stack replacement costs incurred during the period), PPA operating costs and LCM adjustments.
Service agreements and aftermarket costs, net of revenues, totaled $14.4 million for the fiscal
year ended October 31, 2009 compared to $19.9 million in the same period of the prior year. The
decrease in net service agreement and aftermarket costs is primarily due to lower stack replacement
costs. In fiscal year 2008, we began producing a five-year fuel cell stack and are now using these
stacks in our current power plants.
Research and development contracts
Research and development contracts revenue is derived primarily (greater than 90 percent) from the
DOE and other governmental agencies. Research and development contracts revenue and related costs
for the fiscal years ended October 31, 2009 and 2008 were as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended |
|
|
|
|
|
|
October 31, |
|
|
Percentage |
|
|
|
2009 |
|
|
2008 |
|
|
change |
|
|
|
Research and development contracts |
|
$ |
14,212 |
|
|
$ |
17,987 |
|
|
|
(21 |
)% |
Cost of research and development contracts |
|
|
10,994 |
|
|
|
16,059 |
|
|
|
(32 |
)% |
|
|
|
|
|
|
|
|
|
|
|
Gross margin |
|
$ |
3,218 |
|
|
$ |
1,928 |
|
|
|
67 |
% |
|
|
|
|
|
|
|
|
|
|
|
Research and development contracts revenue decreased $3.8 million to $14.2 million for fiscal 2009,
compared to $18.0 million for 2008. Cost of research and development contracts decreased $5.1
million to $11.0 million during fiscal 2009, compared to $16.1 million for 2008. Margin from
research and development contracts for 2009 was $3.2 million or 23 percent, compared to $1.9
million or 11 percent in 2008. The decline in revenue compared to the prior year is due to the
completion of several government programs in the second half of fiscal 2008 and the transition to
the Phase II coal-based SOFC contract that was awarded in January 2009. Phase II of the MW-class
coal-based SOFC contract is a $30.2 million contract of which the DOE has agreed to fund $21.0
million with the remaining amount to be funded by us. The decline in costs and corresponding
margin improvement is due to a lower cost-share requirement for the Phase II coal-based SOFC
contract.
Administrative and selling expenses
Administrative and selling expenses decreased $2.8 million to $17.2 million during fiscal 2009,
compared to $20.0 million in 2008. This decrease is due to lower spending as a result of the cash
management plan implemented in fiscal 2009 and lower share-based compensation expense.
60
Research and development expenses
Research and development expenses decreased $4.3 million to $19.2 million during fiscal 2009,
compared to $23.5 million in 2008. The decrease is related to the cash management plan implemented
in fiscal 2009 and the lower level of engineering effort supporting manufacturing operations, which
is accounted for in cost of goods sold.
Loss from operations
Loss from operations for the fiscal year ended October 31, 2009 was $66.4 million compared to a
loss of $92.8 million in 2008. The reduction is due to a shift of production to lower cost MW-class
products, improved sales margins from cost reductions across all product lines and lower operating
expenses for the reasons noted above.
Loss from equity investments
Our ownership interest in Versa Power Systems, Inc. (Versa) at October 31, 2009 was 39 percent,
unchanged from 2008. We account for the investment under the equity method of accounting. Our share
of equity losses from Versa decreased $1.1 million to $0.8 million in fiscal 2009 compared to $1.9
million in 2008. This decrease was due to lower cost share requirements on research and development
activity being performed by Versa.
Interest and other income, net
Interest and other income, net, decreased to $0.9 million for fiscal 2009 compared to $3.3 million
for 2008 due to lower average invested balances and lower average interest rates.
Provision for income taxes
We have not paid federal or state income taxes in several years due to our history of net operating
losses. During 2009, we began manufacturing products that are expected to be gross margin
profitable on a per unit basis; however, we cannot estimate when production volumes will be
sufficient to generate taxable income. Accordingly, no tax benefit has been recognized related to
current or prior year losses and other deferred tax assets as significant uncertainty exists
surrounding the recoverability of these deferred tax assets. Approximately $4.3 million of our
valuation allowance would reduce additional paid in capital upon subsequent recognition of any
related tax benefits.
As of October 31, 2009, we had $497 million of federal NOL carryforwards that expire in the years
2020 through 2029 and $341 million in state NOL carryforwards that expire in the years 2011 through
2029. We also had $8.1 million of Connecticut state tax credit carryforwards, of which $1 million
expires in 2018. The remaining credits do not expire.
Liquidity and Capital Resources
Our future liquidity will be dependent on obtaining the order volumes and cost reductions necessary
to achieve profitable operations. As a result of product cost reductions, we believe sales volume
of 75 MW to 125 MW will drive the Company to profitability with the lower end of the range
reflecting a sales mix oriented towards complete power plants and the upper end of the range
oriented towards fuel cell components. Actual results will depend on product mix, volume, future
service costs, and market pricing.
We have been engaged in a formal commercial cost-out program since 2003 to reduce the total life
cycle costs of our power plants and have made significant progress primarily through value
engineering our products, manufacturing process improvements, higher production levels, technology
improvements and
global sourcing. During fiscal 2009, we began production of our newest megawatt-class power
plants. These power plants incorporate new fuel cell stacks with outputs of 350 kilowatts (kW)
compared to 300 kW previously, along with lower component and raw material costs. As a result, we
have experienced significant improvement in our margins and cost ratios as product sales in 2010
were gross margin positive on a per unit basis.
61
During fiscal 2010, our manufacturing run-rate was an annualized 22 MW, compared to 30 MW in fiscal
2009 to match production with customer delivery requirements on remaining backlog. Our sales and
service backlog as of October 31, 2010 was approximately $154 million compared to approximately $91
million as of October 31, 2009. In response to the increased level of domestic orders received in
2010 and anticipating additional orders from POSCO Power, we increased our production run rate to
35 megawatts per year during the fourth quarter of fiscal year 2010.
By investing $5 million to $7 million for upgrades and maintenance of production assets, maximizing
existing assets, operating at full capacity (e.g multiple shifts 24 hours per day, up to 7 days a
week) and making other improvements, we estimate that we can increase capacity from 70 MW to 90 MW
of annual production. With increasing order flow, our plan has been to expand production capacity
to 150 MW within our existing Torrington facility. This expansion would require the addition of
equipment (e.g. furnaces, tapecasting and other equipment) to increase the capacity of certain
operations. Due to the economies of scale and equipment required, we believe it is more cost
effective to add capacity in large blocks. We estimate that the expansion to 150 MW will require
additional capital investments of $35 to $45 million although, this expansion may occur in stages
depending on the level of market demand.
In addition to increasing annual order volume and reducing product costs, we may also raise capital
through debt or equity offerings; however, there can be no assurance that we will be able to obtain
additional capital in the future. The timing and size of any financing will depend on multiple
factors including market conditions, future order flow and the need to adjust production capacity.
If we are unable to raise additional capital, our growth potential may be adversely affected and we
may have to modify our plans. We anticipate that our existing capital resources, together with
anticipated revenues and cash flows, will be adequate to satisfy our financial requirements and
agreements through at least the next twelve months.
Cash Flows
Cash, cash equivalents, and investments in U.S. treasuries totaled approximately $54.6 million as
of October 31, 2010 compared to $64.8 million as of October 31, 2009. Net cash and investments
used during the year ended October 31, 2010 was $10.3 million compared to $22.1 million during
fiscal 2009. We received cash inflow from the following equity offering in fiscal 2010:
|
|
|
In July 2010, we received $32.1 million, net of underwriting discounts, commissions and
offering expenses, from an underwritten public offering of 27,600,000 shares of common
stock at $1.25 per share. |
Excluding this offering, our use of net cash and investments for the fiscal year totaled $42.4
million. As a result of reduced product costs and expected cash flow on existing contract backlog
and improvements in the U.S. market that is driving increased production levels, we expect that
cash use, excluding equity offerings, will be reduced from fiscal 2010 levels. Actual quarterly
cash use is impacted by numerous factors including the timing of new orders and customer payments,
changes in working capital, capital spending and the factory production rate.
62
Cash, cash equivalents, and investments in U.S. Treasuries at October 31, 2010 and 2009 were as
follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended |
|
|
|
|
|
|
October 31, |
|
|
|
|
|
|
2010 |
|
|
2009 |
|
|
Change |
|
Cash and cash equivalents |
|
$ |
20,467 |
|
|
$ |
57,823 |
|
|
$ |
(37,356 |
) |
U.S. Treasuries |
|
|
34,090 |
|
|
|
7,004 |
|
|
|
27,086 |
|
|
|
|
|
|
|
|
|
|
|
Total |
|
$ |
54,557 |
|
|
$ |
64,827 |
|
|
$ |
(10,270 |
) |
|
|
|
|
|
|
|
|
|
|
Cash and cash equivalents at October 31, 2010 totaled $20.5 million, reflecting a decrease of $37.4
million from October 31, 2009. We have pledged approximately $9.0 million of our cash and cash
equivalents as collateral and letters of credit for certain banking requirements and contracts. As
of October 31, 2010, outstanding letters of credit totaled $7.3 million. These expire on various
dates through May 2012. The key components of our cash inflows and outflows from operations were
as follows:
Operating Activities During fiscal 2010, we used $35.0 million in cash for operating
activities, compared to $65.2 million of cash used during 2009. Cash used in operating
activities during fiscal 2010 consisted of the net loss for the year of $56.3 million and
changes in net working capital of $6.7 million partially offset by non-cash charges totaling
$14.6 million.
Changes in working capital improved through decreased accounts receivable of $4.5 million
and increased deferred revenue of $6.4 million due to milestone payments primarily related
to our POSCO product and sales contracts. Also benefiting working capital was higher
accounts payable and accrued expenses of $4.5 million. These working capital improvements
were partially offset by higher inventory of $7.9 million related to product in inventory
not yet applied to customer contracts and higher other assets of $0.8 million. Non-cash
charges consisted primarily of share-based compensation of $2.9 million, increase in
carrying value of equity investment and redeemable minority interest of $3.1 million,
depreciation expense of $7.4 million, impairment on fixed assets of $0.8 million and
increase in the allowance for doubtful accounts of $0.4 million.
During fiscal 2009, we used $65.2 million in cash for operating activities, compared to
$61.4 million of cash used during 2008. Cash used in operating activities during fiscal 2009
consisted of the net loss for the year of $68.7 million and changes in net working capital
of $13.8 million partially offset by non-cash charges totaling $17.3 million.
Investing Activities During fiscal 2010, net cash used in investing activities totaled
$30.3 million compared to $37.8 million of cash provided in 2009. Cash used in investing
activities in 2010 consisted of new U.S. Treasury purchases of $59.7 million partially
offset by the maturity of $32.5 million of investments in U.S. treasury securities, capital
expenditures of $2.5 million and a convertible debt investment in Versa of $0.6 million.
During fiscal 2009, net cash provided by investing activities totaled $37.8 million compared
to $3.8 million of cash provided in 2008. Cash provided by investing activities in 2009
consisted of the maturity of $41.0 million of investments in U.S. treasury securities
partially offset by capital expenditures of $2.6 million and a convertible debt investment
in Versa of $0.6 million.
Financing Activities During fiscal 2010, net cash provided by financing activities totaled
$27.9 million compared to $47.2 million in 2009. Cash provided by financing activities
during 2010 consisted primarily of $32.1 million from the sale and issuance of common stock
partially offset by the payment of preferred stock dividends of $3.7 million, debt repayment
of $0.4 million and restricted stock transactions of $0.2 million.
63
During fiscal 2009, net cash provided by financing activities totaled $47.2 million compared
to $2.6 million in 2008. Cash provided by financing activities during 2009 consisted
primarily of $50.3 million from the sale and issuance of common stock partially offset by
the payment of preferred stock dividends of $3.6 million. As previously discussed, we raised
$22.5 million, net of fees, from the sale of common stock in a direct registered stock
offering and POSCO purchased $25.0 million of our common stock in connection with the
execution of the 2009 License Agreement.
Sources and Uses of Cash and Investments
We continue to invest in new product and market development and, as such, we are not currently
generating positive cash flow from operations. Our operations are funded primarily through sales
of equity and debt securities, cash generated from product sales, service contracts and PPAs,
incentive funding, government research and development contracts, and interest earned on
investments. In order to produce positive cash flow from operations, we need to be successful at
increasing annual order volume and implementing our cost reduction efforts as well as continuing
involvement in research and development contracts. Status of these activities is described below.
On
January 13, 2011 we closed on a registered direct offering with an
institutional investor for the sale of 10,160,428 units at a
negotiated price of $1.87 per unit (gross proceeds of $19.0
million), with each unit consisting of (i) one share of its common
stock, par value $0.0001 per share (Common Stock) and (ii)
one warrant to purchase 1.0 share of Common Stock. The net proceeds
from the sale of the units, after deducting the placement agent fees
and other estimated offering expenses, will be approximately $17.8
million. We intend to use the proceeds from this offering for product
development, project financing, expansion of manufacturing capacity,
and general corporate purposes.
Increasing annual order volume
We need to increase annual order volume to achieve profitability. Increased production volumes
lower costs by leveraging supplier/purchasing opportunities, creating opportunities for
incorporating manufacturing process improvements, and spreading fixed costs over more units. Our
overall manufacturing process (module manufacturing, final assembly, testing and conditioning) has
a production capacity of 70 MW per year.
Refer to Recent Development for updates on our key markets (South Korea, California and
Connecticut) and information on our government research and development projects.
Cost reduction efforts
Product cost reductions are essential for us to more fully penetrate the market for our fuel cell
products and attain profitability. Cost reductions will also reduce or eliminate the need for
incentive funding programs which currently allow us to price our products to compete with
grid-delivered power and other distributed generation technologies. Product cost reductions come
from several areas:
|
|
|
engineering improvements; |
|
|
|
|
technology advances; |
|
|
|
|
supply chain management; |
|
|
|
|
production volume; and |
|
|
|
|
manufacturing process improvements. |
We continually strive to reduce product costs and increase power output of our products. As
previously mentioned, we began production of our newest megawatt-class power plants during fiscal
2009, which incorporate higher output stacks and lower component and raw material costs. Also in
2009, we introduced a five-year fuel cell stack which is expected to reduce our long-term service
costs. We are also developing and expect to bring to market products with a stack life greater
than five-years. Extending stack life increases the sales value of the product and reduces service
costs.
Continued involvement in research and development contracts
Our research and development contracts are generally multi-year, cost reimbursement contracts. The
majority of these are U.S. Government contracts that are dependent upon the governments continued
allocation of funds and may be terminated in whole or in part at the convenience of the government.
We
will continue to seek research and development contracts, and to obtain these contracts, we must
continue to prove the benefits of our technologies and be successful in our competitive bidding.
64
Commitments and Significant Contractual Obligations
A summary of our significant future commitments and contractual obligations as of October 31, 2010
and the related payments by fiscal year is summarized as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Payments Due by Period |
|
|
|
|
|
|
|
|
Less than |
|
|
1 - 3 |
|
|
3 - 5 |
|
|
More Than |
|
Contractual Obligations |
|
|
Total |
|
|
1 year |
|
|
years |
|
|
years |
|
|
5 years |
|
|
|
Capital and operating lease commitments (1) |
|
|
$ |
3,731 |
|
|
$ |
872 |
|
|
$ |
1,563 |
|
|
$ |
1,221 |
|
|
$ |
75 |
|
Term loans (principal and interest) |
|
|
|
5,703 |
|
|
|
1,044 |
|
|
|
730 |
|
|
|
761 |
|
|
|
3,168 |
|
Purchase commitments (2) |
|
|
|
43,843 |
|
|
|
36,755 |
|
|
|
7,088 |
|
|
|
|
|
|
|
|
|
Series B Preferred dividends payable (3) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Series 1 Preferred dividends payable (4) |
|
|
|
24,224 |
|
|
|
12,875 |
|
|
|
2,454 |
|
|
|
2,454 |
|
|
|
6,441 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total |
|
|
$ |
77,501 |
|
|
$ |
51,546 |
|
|
$ |
11,835 |
|
|
$ |
4,436 |
|
|
$ |
9,684 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(1) |
|
Future minimum lease payments on capital and operating leases. |
|
(2) |
|
Purchase commitments with suppliers for materials, supplies and services incurred in
the normal course of business. |
|
(3) |
|
We are currently paying $3.2 million in annual dividends on our Series B Preferred
Stock. Dividends on Series B Preferred Stock accrue at an annual rate of 5 percent and are
paid quarterly. On or after November 20, 2009 we may, at our option, cause shares of our
Series B Preferred Stock to be automatically converted into that number of shares of our
common stock that are issuable at the then prevailing conversion rate. We may exercise our
conversion right only if the closing price of our common stock exceeds 150 percent of the
then prevailing conversion price ($11.75 at November 20, 2009) for 20 trading days during
any consecutive 30 trading day period, as described in the certificate of designation for
the Series B Preferred Stock. The $3.2 million annual dividend payment has not been
included as we cannot reasonably determine when and if we will be able to convert the
Series B Preferred Stock into shares of our common stock. |
|
(4) |
|
Annual dividends of Cdn.$1.25 million ($1.16 million based on the October 31, 2010
exchange rate of Cdn.$0.98 to U.S.$1.00) accrue on the Series 1 Preferred Stock. We have
agreed to pay a minimum of Cdn.$500,000 ($465,000 based on an exchange rate of Cdn.$0.98 to
U.S.$1.00) in cash or common stock annually to Enbridge, the holder of the Series 1
Preferred Stock, so long as Enbridge holds the shares. Interest accrues on cumulative
unpaid dividends at an annual rate of 9 percent until payment thereof. All cumulative
unpaid dividends originally had to be paid by December 31, 2010. Using an exchange rate of
Cdn.$1.0 to U.S.$1.00 (approximate exchange rate on December 31, 2010), cumulative unpaid
dividends and accrued interest on the Series 1 Preferred Shares was $12.5 million as of
December 31, 2010. In December 2010, Enbridge agreed to extend the payment deadline to
January 31, 2011. The Company and Enbridge are in negotiations to modify certain terms of
the Series 1 preferred share agreement. The payment amounts above assume (i) that the
minimum dividend payments are made through December 31, 2010, (ii) that all cumulative
unpaid dividends and accrued interest are paid on December 31, 2010, (iii) that the annual
dividend of Cdn.$1.25 million is paid thereafter, and (iv) an exchange rate of Cdn.$0.98 to
U.S.$1.00. We have the option of paying these amounts in common stock or cash. |
In April 2008, we entered into a new 10-year loan agreement with the Connecticut Development
Authority allowing for a maximum amount borrowed of $4.0 million. At October 31, 2010, we had an
outstanding balance of $3.8 million on this loan. The stated interest rate is 5 percent and the
loan will be collateralized by the assets procured under this loan as well as $4.0 million of
additional machinery and equipment. Repayment terms require (i) interest only payments on
outstanding balances through November 2009 and (ii) interest and principal payments commencing in
December 2009 through May 2018.
65
Bridgeport FuelCell Park, LLC (BFCP), one of our wholly-owned subsidiaries, has an outstanding
loan with the Connecticut Clean Energy Fund, secured by assets of BFCP. Interest accrues monthly
at an annual rate of 8.75 percent and repayment of principal and accrued interest is not required
until the
occurrence of certain events. As of October 31, 2010, no repayments of principal and interest have
been made and we cannot reasonably determine when such repayments will begin. The outstanding
balance on this loan, including accrued interest, is $0.7 million as of October 31, 2010.
In June 2010 the Company entered into an agreement with Marubeni Corporation to return certain
advance contract payments, resolve claims for services and repurchase surplus inventory items
previously sold to Marubeni Corporation. The agreement called for payments of approximately $1.9
million to Marubeni Corporation between June and December 2010 and a payment of $1.0 million upon
title transfer of surplus inventory to FuelCell. Payments due under this agreement as of October
31, 2010 are recorded as accrued expenses. The Company did not incur a charge to the consolidated
statement of operations for this agreement. Terms of the agreement were completed in December of
2010.
We have pledged approximately $9.0 million of our cash and cash equivalents as collateral and
letters of credit for certain banking requirements and contracts. As of October 31, 2010,
outstanding letters of credit totaled $7.3 million. These expire on various dates through May
2012.
We have identified uncertain tax positions aggregating $15.7 million and reduced our NOLs by this
amount. Because of the level of NOLs and valuation allowances, unrecognized tax benefits, even if
not resolved in our favor, would not result in any cash payment or obligation and therefore have
not been included in the contractual obligation table above.
In addition to the commitments listed in the table above, we have the following outstanding
obligations:
Power purchase agreements
As of October 31, 2010, we had 2.5 MW of power plant installations under PPAs ranging in duration
from five to ten years. As owner of the power plants, we are responsible for all operating costs
necessary to maintain, monitor and repair the power plants. Under certain agreements, we are also
responsible for procuring fuel, primarily natural gas, to run the power plants.
We qualified for incentive funding for these projects in California under the states SGIP and
other government programs. Funds are payable upon commercial installation and demonstration of the
plant and may require return of the funds for failure of certain performance requirements during
the period specified by the government program. Revenue related to these incentive funds is
recognized ratably over the performance period. As of October 31, 2010 we had deferred revenue
totaling $1.0 million related to incentive funding received on PPAs, which will be earned and
recognized in fiscal 2011.
Service and warranty agreements
We warranty our products for a specific period of time against manufacturing or performance
defects. Our standard warranty period is generally 15 months after shipment or 12 months after
installation of the product. In addition to the standard product warranty, we have contracted with
certain customers to provide services to ensure the power plants meet minimum operating levels for
terms ranging from one to 20 years. Our standard LTSA term is five years. Pricing for service
contracts is based upon estimates of future costs. Also see Critical Accounting Policies and
Estimates for additional details.
66
Research and development cost-share contracts
We have contracted with various government agencies to conduct research and development as either a
prime contractor or sub-contractor under multi-year, cost-reimbursement and/or cost-share type
contracts or cooperative agreements. Cost-share terms require that participating contractors share
the total cost of the project based on an agreed upon ratio. In many cases, we are reimbursed only
a portion of the costs incurred or to be incurred on the contract. While government research and
development contracts may extend for many years, funding is often provided incrementally on a
year-by-year basis if contract terms are met and Congress authorizes the funds. As of October 31,
2010, research and development sales backlog totaled $9.7 million, of which $5.3 million is funded.
Should funding be delayed or if business initiatives change, we may choose to devote resources to
other activities, including internally funded research and development.
Health Care Reform Acts
In March 2010, the President of the United States signed the Patient Protection and Affordable Care
Act and the Health Care and Education Reconciliation Act of 2010 (collectively the 2010 Acts).
The 2010 Acts will have a substantial impact on health care providers, insurers, employers and
individuals. The 2010 Acts will impact employers and businesses differently depending on the size
of the organization and the specific impacts on a companys employees. Certain provisions of the
2010 Acts became effective during our open enrollment period (November 1, 2010) while other
provisions of the 2010 Acts will be effective in future years. The 2010 Acts could require, among
other things, changes to our current employee benefit plans, our information technology
infrastructure, and in our administrative and accounting processes. The ultimate extent and cost
of these changes cannot be determined at this time and are being evaluated and updated as related
regulations and interpretations of the 2010 Acts become available.
Critical Accounting Policies and Estimates
We prepare our financial statements in conformity with accounting principles generally accepted in
the United States. The preparation of financial statements and related disclosures requires
management to make estimates and assumptions that affect the reported amounts of assets,
liabilities, revenues and expenses and the disclosure of contingent assets and liabilities. Actual
results could differ from those estimates. Estimates are used in accounting for, among other
things, revenue recognition, contract loss reserves, excess, slow-moving and obsolete inventories,
product warranty costs, reserves on long-term service agreements, share-based compensation expense,
allowance for doubtful accounts, depreciation and amortization, long-lived asset impairments and
contingencies. Estimates and assumptions are reviewed periodically, and the effects of revisions
are reflected in the consolidated financial statements in the period they are determined to be
necessary.
We believe that the following discussion represents our critical accounting policies and estimates.
Revenue Recognition
We earn revenue from (i) the sale and installation of fuel cell power plants and modules (ii) sale
of component part kits and spare parts to customers, (iii) site engineering and construction
services (iv) providing services under long-term service agreements (LTSA), (v) the sale of
electricity under power purchase agreements (PPA) as well as incentive revenue from the sale of
electricity under PPAs, and (vi) customer-sponsored research and development projects. Our revenue
is primarily generated from customers located throughout the U.S. and Asia and from agencies of the
U.S. government. Revenue from customer-sponsored research and development projects is recorded as
research and development contracts revenue and all other revenues are recorded as product sales and
revenues in the consolidated statements of operations.
67
Revenue from sales of our DFC power plants and modules are recognized under the percentage of
completion method of accounting. Revenues are recognized proportionally as costs are incurred and
assigned to a customer contract by comparing total expected costs for each contract to the total
contract value. Prior to fiscal 2010, we did not provide for a contract loss reserve on product
sales contracts as products were in their early stages of development and market acceptance, and
the total costs and timing of production for product sales contracts as well as installation and
commissioning of these units could not be reasonably estimated. However, upon procurement of
inventory for fulfillment of a product sales contract, the Company recorded such inventory at the
lower of cost or market. As a result of a more consistent production rate and predictable timing
for fulfillment of product sales contracts and more installation and commissioning experience for
our major product lines, effective November 1, 2009 a contract loss reserve on product sales
contracts is recognized at the time we become aware that estimated total costs are expected to
exceed the contract sales price. As of October 31, 2010, the estimated contract loss reserve
totaled approximately $0.6 million. Actual results could vary from initial estimates and reserve
estimates will be updated as we gain further manufacturing and operating experience.
Revenue from component part kits and spare parts sales is recognized upon shipment and title
transfer under the terms of the customer contract.
Revenue from LTSA contracts for power plants with our 5-year stack design is earned ratably over
the term of the contract by performing routine monitoring and maintenance and by meeting a certain
level of power output. For our legacy LTSA contracts on power plants with our older 3-year stack
design, a portion of the contract value related to the stack replacement has been deferred. Upon
stack replacement, revenue is recognized ratably over the remaining contract term. Revenue related
to routine monitoring and maintenance under legacy contracts is recognized ratably over the full
term of the contract.
Revenue from the sale of electricity is recognized as electricity is provided to the customer.
Incentive revenue is recognized ratably over the term of the PPA. Site engineering and construction
services revenue is recognized on percentage of completion as costs are incurred.
Revenue from research and development contracts is recognized proportionally as costs are incurred
and compared to the estimated total research and development costs for each contract. Revenue from
government funded research, development and demonstration programs are generally multi-year,
cost-reimbursement and/or cost-shared type contracts or cooperative agreements. We are reimbursed
for reasonable and allocable costs up to the reimbursement limits set by the contract or
cooperative agreement, and on certain contracts we are reimbursed only a portion of the costs
incurred. While government research and development contracts may extend for many years, funding
is often provided incrementally on a year-by-year basis if contract terms are met and Congress has
authorized the funds.
Inventories and Advance Payments to Vendors
Inventories consist principally of raw materials and work-in-process and are stated at the lower of
cost or market. In certain circumstances, we will make advance payments to vendors for future
inventory deliveries. These advance payments (net of related reserves) are recorded as other
current assets on the consolidated balance sheets.
Prior to November 1, 2009, we provided for a lower of cost or market (LCM) reserve to the cost
basis of inventory at the time of purchase as our products were historically sold below cost.
During the second half of 2009, we began production of our newest megawatt-class power plants and
modules. The manufactured cost per kilowatt of these products is lower than previous models due to
a 17 percent power increase and lower component and raw materials cost and are expected to be gross
margin positive on a unit by unit basis. As a result, beginning in fiscal 2010, we revised our
method of estimating contract losses and no longer provide for an LCM reserve on new inventory
purchased.
68
As of October 31, 2010 and October 31, 2009, the LCM adjustment to the cost basis of inventory and
advance payments to vendors was $5.0 million and $9.5 million, respectively, which equates to a
reduction of 12 and 25 percent, respectively, of the gross inventory and advance payments to
vendors value. As inventory is utilized in finished products and sold and used to service LTSAs,
the Company expects the LCM reserve to continue to decline.
Warranty and Service Expense Recognition
We warranty our products for a specific period of time against manufacturing or performance
defects. Our warranty is limited to a term generally 15 months after shipment or 12 months after
installation of our products. We reserve for estimated future warranty costs based on historical
experience. We also provide for a specific reserve if there is a known issue requiring repair
during the warranty period. Given our limited operating experience, particularly for newer product
designs, actual results could vary from initial estimates. Estimates used to record warranty
reserves are updated as we gain further operating experience. As of October 31, 2010 and October
31, 2009, the warranty reserve, which is classified in accrued liabilities on the consolidated
balance sheet totaled $0.7 million and $0.5 million, respectively.
In addition to the standard product warranty, we have entered into LTSA contracts with certain
customers to provide monitoring, maintenance and repair services for fuel cell power plants ranging
from one to 20 years. Our standard service agreement term is five years. Under the terms of our
LTSA, the power plant must meet a minimum operating output during the term. If minimum output
falls below the contract requirement, we may be subject to performance penalties or may be required
to repair or replace the customers fuel cell stack. The Company has provided for a reserve for
performance guarantees which based on historical fleet performance totaled $1.2 million and $0.9
million as of October 31, 2010 and 2009, respectively.
For our legacy LTSA contracts on power plants with our older 3-year stack design, the Company has
accrued a reserve based on estimated future stack replacement and service costs in excess of the
contract value. We expect the replacement of older stacks produced prior to the five-year stack
design will continue into mid 2012. Reserve estimates for future costs associated with maintaining
legacy service agreements are determined based on a number of factors including the estimated life
of the stack, used replacement stacks available, our limit of liability on service agreements and
the customers future operating plans for the power plant. Our reserve estimates include cost assumptions
based on what we anticipate the service requirements will be to fulfill obligations on a contract by contract basis,
which in many cases is in excess of our contractual limit of liability under LTSAs which is limited to the
amount of service fees payable under the contract. As of October 31, 2010, our reserve on LTSA
contracts totaled $6.6 million compared to $6.0 million as of October 31, 2009.
LTSAs for power plants that have our five-year stack design are not expected to require a stack
change to continue to meet minimum operating levels during the initial five-year term of the
contract, although we have limited operating experience with these products. Stack replacements for
new agreements which include the five-year stack design are expected to only be required upon
renewal of the service agreement by the customer.
At the end of our LTSA contracts, customers are expected to either renew the contract or we
anticipate that the stack module or the entire power plant will be returned to the Company as the
plant is no longer being monitored or having routine service performed. In situations where the
customer agrees at the time of a restack to return the stack to the Company at the end of the LTSA
term, the cost of the stack is recorded as a long-term asset and depreciated over its expected
life. If the Company does not obtain rights to title from the customer, the cost of the stack is
expensed at the time of restack. During fiscal 2010, depreciation on stacks recorded as long-term
assets totaled $0.1 million. As of October 31, 2010,
the total remaining stack value recorded as a long-term asset was $2.0 million. This balance is
expected to increase over time as stack replacements occur.
69
Share-Based Compensation
We account for restricted stock awards (RSAs) based on the closing market price of the Companys
common stock on the date of grant. We account for stock options awarded to employees and
non-employee directors under the fair value method of accounting using the Black-Scholes valuation
model to estimate fair value at the grant date. The model requires us to make estimates and
assumptions regarding the expected life of the option, the risk-free interest rate, the expected
volatility of our common stock price and the expected dividend yield. The fair value of equity
awards is amortized to expense over the vesting period, generally four years. Share-based
compensation was $3.0 million, $4.8 million and $5.5 million for the fiscal years ended October 31,
2010, 2009 and 2008, respectively.
Income Taxes
Income taxes are accounted for under the liability method. Deferred tax assets and liabilities are
determined based on net operating loss (NOL) carryforwards, research and development credit
carryforwards, and differences between financial reporting and income tax bases of assets and
liabilities. Deferred tax assets and liabilities are measured using enacted tax rates and laws
expected to be in effect when the differences are expected to reverse. The effect on deferred tax
assets and liabilities of a change in tax rates is recognized in income in the period that includes
the enactment date. A valuation allowance is recorded against deferred tax assets if it is
unlikely that some or all of the deferred tax assets will be realized.
As of November 1, 2007, we adopted guidance for how a company should recognize, measure, present,
and disclose in its financial statements uncertain tax positions that the company has taken or
expects to take on a tax return (including a decision whether to file or not file a return in a
particular jurisdiction). The companys financial statements should reflect expected future tax
consequences of such positions presuming the taxing authorities full knowledge of the position and
all relevant facts.
The evaluation of a tax position is a two-step process. The first step is recognition: the company
determines whether it is more likely than not that a tax position will be sustained upon
examination, including resolution of any related appeals or litigation processes, based on the
technical merits of the position. The second step is measurement: a tax position that meets the
more likely than not recognition threshold is measured to determine the amount of benefit to
recognize in the financial statements. The tax position is measured at the largest amount of
benefit that is greater than 50 percent likely of being realized upon ultimate settlement.
Accounting Guidance Update
Recently Adopted Accounting Guidance
In April 2008, the Financial Accounting Standards Board (FASB) issued accounting guidance that
amends the factors that should be considered in developing renewal or extension assumptions used to
determine the useful life of a recognized definite-lived intangible asset. In developing
assumptions about renewal or extension options used to determine the useful life of a
definite-lived intangible asset, a company needs to consider its own historical experience adjusted
for company-specific factors. In the absence of that experience, the company shall consider the
assumptions that market participants would use about renewal or extension options. The new guidance
was effective for the first quarter of fiscal 2010. We currently do not have any intangible assets
recorded in our consolidated balance sheets; therefore, the impact of this guidance on our
consolidated financial statements will be determined when and if we acquire definite-lived
intangible assets.
70
In December 2007, the FASB issued new guidance that requires noncontrolling interests (formerly
minority interests) in a subsidiary be reported as equity in the consolidated financial
statements. Consolidated net income should include the net income for both the parent and the
noncontrolling interest with disclosure of both amounts in the consolidated statements of
operations. The calculation of earnings per share would continue to be based on income amounts
attributable to the parent. This guidance became effective for the quarter ended January 31, 2010
and changed the accounting for and reporting of noncontrolling interests in our subsidiaries.
In December 2007, the FASB issued revised accounting guidance for business combinations that
requires an acquirer to measure the identifiable assets acquired, the liabilities assumed and any
noncontrolling interest in the acquiree at their fair values on the acquisition date, with goodwill
being the excess value over the net identifiable assets acquired. The guidance also requires that
certain other assets and liabilities related to the acquisition, such as contingencies and research
and development, be recorded at fair value. The new guidance was effective for the first quarter of
fiscal 2010. The potential impact of this revised guidance on our consolidated financial
statements will be based upon future business combinations, if any.
Recent Accounting Guidance Not Yet Effective
In April 2010, the FASB provided guidance on defining a milestone and determining when it may be
appropriate to apply the milestone method of revenue recognition for research or development
transactions. Research or development arrangements frequently include payment provisions whereby a
portion or all of the consideration is contingent upon the achievement of milestone events. An
entity may only recognize consideration that is contingent upon the achievement of a milestone in
its entirety in the period the milestone is achieved only if the milestone meets certain criteria.
This guidance is effective prospectively for milestones achieved in fiscal years beginning on or
after June 15, 2010 (November 1, 2010 for the Company). While we are still analyzing the potential
impact of this guidance, we believe that our current practices are consistent with the guidance
and, accordingly, we do not expect the adoption of this guidance will have a material impact on our
financial statements.
In January 2010, the FASB issued guidance that requires new disclosures for fair value measurements
and provides clarification for existing disclosure requirements. This amended guidance require
disclosures about inputs and valuation techniques used to measure fair value as well as disclosures
about significant transfers in and out of Levels 1 and Levels 2 fair value measurements and
disclosures about the purchase, sale, issuance and settlement activity of Level 3 fair value
measurements. This guidance is effective for interim and annual reporting periods beginning after
December 15, 2009, except for disclosures about the purchase, sale, issuance and settlement
activity of Level 3 fair value measurements, which is effective for fiscal years beginning after
December 15, 2010. The Company was not impacted by the disclosures effective for interim periods
beginning after December 15, 2009 and we do not expect the remaining disclosures required after
December 15, 2010 upon adoption of this guidance will have a material impact on our financial
statements or disclosures.
In December 2009, the FASB issued revised guidance related to the consolidation of variable
interest entities (VIE). The revised guidance requires reporting entities to evaluate former
qualified special
purpose entities for consolidation, changes the approach to determining a VIEs primary beneficiary
from a quantitative assessment to a qualitative assessment designed to identify a controlling
financial interest, and increases the frequency of required reassessments to determine whether a
company is the primary beneficiary of a VIE. It also clarifies, but does not significantly change,
the characteristics that identify a VIE. The guidance is effective as of the beginning of a
companys first fiscal year beginning after November 15, 2009 (November 1, 2010 for the Company),
and for subsequent interim and annual reporting periods. We do not expect this new guidance will
have an impact on our financial statements.
71
In October 2009, the FASB issued guidance updating accounting standards for revenue recognition for
multiple-deliverable arrangements. The stated objective of the update was to address the
accounting for multiple-deliverable arrangements to enable vendors to account for products or
services separately rather than as a combined unit. The guidance provides amended methodologies
for separating consideration in multiple-deliverable arrangements and expands disclosure
requirements. The guidance will be effective prospectively for revenue arrangements entered into
or materially modified in fiscal years beginning on or after June 15, 2010 (November 1, 2010 for
the Company), with early adoption permitted. We do not expect this guidance will have an impact on
our financial statements or disclosures.
In June 2009, the FASB issued accounting guidance which requires a company to perform ongoing
reassessment of whether it is the primary beneficiary of a variable interest entity (VIE).
Specifically, the guidance modifies how a company determines when an entity that is insufficiently
capitalized or is not controlled through voting (or similar rights) should be consolidated. The
guidance clarifies that the determination of whether a company is required to consolidate a VIE is
based on, among other things, an entitys purpose and design and a companys ability to direct the
activities of the VIE that most significantly impact the VIEs economic performance. The guidance
requires an ongoing reassessment of whether a company is the primary beneficiary of a VIE and
enhanced disclosures of the companys involvement in VIEs and any significant changes in risk
exposure due to that involvement. The guidance will be effective for the first quarter of fiscal
2011. We do not expect this new guidance will have an impact on our financial statements.
72
Item 7A. QUANTITATIVE AND QUALITATIVE DISCLOSURES ABOUT MARKET RISK
Interest Rate Exposure
We typically invest in U.S. Treasury securities with maturities ranging from less than three months
to one year or more. We expect to hold these investments until maturity and accordingly, these
investments are carried at cost and not subject to mark-to-market accounting. At October 31, 2010,
our U.S. Treasury investments had a carrying value of $34.1 million and maturity dates ranging from
November 18, 2010 to March 15, 2012. The fair value of these securities at October 31, 2010
approximated their carrying value. At October 31, 2009, our U.S. Treasury investments had a
carrying value of $7.0 million and maturity dates ranging from December 31, 2009 to April 30, 2010.
The fair value of these securities at October 31, 2009 approximated their carrying value. Cash is
invested overnight with high credit quality financial institutions and therefore we are not exposed
to market risk from changing interest rates. Based on our overall interest rate exposure at
October 31, 2010, including all interest rate sensitive instruments, a change in interest rates of
one percent would affect our results of operations by $0.2 million.
Foreign Currency Exchange Risk
As of October 31, 2010, less than one percent of our total cash, cash equivalents and investments
were in currencies other than U.S. dollars (Canadian dollars and South Korean Won). We make
purchases from certain vendors in currencies other than U.S. dollars. Although we have not
experienced significant foreign exchange rate losses to date, we may in the future, especially to
the extent that we do not engage in currency hedging activities. The economic impact of currency
exchange rate movements on our operating results is complex because such changes are often linked
to variability in real growth, inflation, interest rates, governmental actions and other factors.
These changes, if material, may cause us to adjust our financing and operating strategies.
Derivative Fair Value Exposure
Series 1 Preferred Stock
Our Series 1 Preferred shares include embedded derivatives that require bifurcation from the host
contract. Specifically, the embedded derivatives requiring bifurcation from the host contract
include the conversion feature of the security and the variable dividend obligation. The aggregate
fair value of these derivatives included within long-term debt and other liabilities in our
consolidated balance sheets as of October 31, 2010 and 2009 was $0.5 million. The fair value was
based on valuation models using various assumptions including historical stock price volatility,
risk-free interest rate and a credit spread based on the yield indexes of technology high yield
bonds, foreign exchange volatility as the Series 1 Preferred security is denominated in Canadian
dollars, and the closing price of our common stock. Changes in any of these assumptions would
change the underlying fair value with a corresponding charge or credit to earnings. However, any
changes to the assumptions are not expected to have a material effect on our results of operations
or financial condition.
Warrants
In connection with our investment in Versa, we received warrants for the right to purchase
additional shares of Versas common stock. At October 31, 2010 and 2009, we held warrants for the
right to purchase 3,969 and 3,108 shares of Versas common stock, respectively. We have determined
that these warrants represent derivatives. The fair value of the warrants is based on the
Black-Scholes valuation model using historical stock price, volatility (based on a peer group since
Versas common stock is not publicly traded) and risk-free interest rate assumptions. The fair
value of the warrants at October 31, 2010 and 2009 was $0.2 million and was included within
investment and loan to affiliate in our consolidated balance sheets. Changes in any of these
assumptions would result in a change in the fair value of the warrants and impact our results of
operations; however; the impact is not expected to be material. For example, a 10 percent increase
in the volatility assumption would have resulted in a charge to earnings of $20 thousand, assuming
all other assumptions remain the same.
73
Item 8. CONSOLIDATED FINANCIAL STATEMENTS AND SUPPLEMENTARY DATA
|
|
|
|
|
Index to the Consolidated Financial Statements |
|
Page |
|
|
|
|
|
|
|
|
|
75 |
|
|
|
|
|
|
|
|
|
76 |
|
|
|
|
|
|
|
|
|
77 |
|
|
|
|
|
|
|
|
|
78 |
|
|
|
|
|
|
|
|
|
79 |
|
|
|
|
|
|
|
|
|
80 |
|
|
|
|
|
|
74
Report of Independent Registered Public Accounting Firm
The Board of Directors and Stockholders
FuelCell Energy, Inc.:
We have audited the accompanying consolidated balance sheets of FuelCell Energy, Inc. and
subsidiaries as of October 31, 2010 and 2009, and the related consolidated statements of
operations, changes in equity, and cash flows for each of the years in the three-year period ended
October 31, 2010. We also have audited FuelCell Energy, Inc.s internal control over financial
reporting as of October 31, 2010, based on criteria established in Internal Control Integrated
Framework issued by the Committee of Sponsoring Organizations of the Treadway Commission (COSO).
FuelCell Energy, Inc.s management is responsible for these consolidated financial statements, for
maintaining effective internal control over financial reporting, and for its assessment of the
effectiveness of internal control over financial reporting, included in the accompanying management
report on internal controls over financial reporting. Our responsibility is to express an opinion
on these consolidated financial statements and an opinion on the Companys internal control over
financial reporting based on our audits.
We conducted our audits in accordance with the standards of the Public Company Accounting Oversight
Board (United States). Those standards require that we plan and perform the audits to obtain
reasonable assurance about whether the financial statements are free of material misstatement and
whether effective internal control over financial reporting was maintained in all material
respects. Our audits of the consolidated financial statements included examining, on a test basis,
evidence supporting the amounts and disclosures in the financial statements, assessing the
accounting principles used and significant estimates made by management, and evaluating the overall
financial statement presentation. Our audit of internal control over financial reporting included
obtaining an understanding of internal control over financial reporting, assessing the risk that a
material weakness exists, and testing and evaluating the design and operating effectiveness of
internal control based on the assessed risk. Our audits also included performing such other
procedures as we considered necessary in the circumstances. We believe that our audits provide a
reasonable basis for our opinions.
A companys internal control over financial reporting is a process designed to provide reasonable
assurance regarding the reliability of financial reporting and the preparation of financial
statements for external purposes in accordance with generally accepted accounting principles. A
companys internal control over financial reporting includes those policies and procedures that (1)
pertain to the maintenance of records that, in reasonable detail, accurately and fairly reflect the
transactions and dispositions of the assets of the company; (2) provide reasonable assurance that
transactions are recorded as necessary to permit preparation of financial statements in accordance
with generally accepted accounting principles, and that receipts and expenditures of the company
are being made only in accordance with authorizations of management and directors of the company;
and (3) provide reasonable assurance regarding prevention or timely detection of unauthorized
acquisition, use, or disposition of the companys assets that could have a material effect on the
financial statements.
Because of its inherent limitations, internal control over financial reporting may not prevent or
detect misstatements. Also, projections of any evaluation of effectiveness to future periods are
subject to the risk that controls may become inadequate because of changes in conditions, or that
the degree of compliance with the policies or procedures may deteriorate.
In our opinion, the consolidated financial statements referred to above present fairly, in all
material respects, the financial position of FuelCell Energy, Inc. and subsidiaries as of October
31, 2010 and 2009, and the results of their operations and their cash flows for each of the years
in the three-year period ended October 31, 2010, in conformity with U.S. generally accepted
accounting principles. Also in our opinion, FuelCell Energy, Inc. maintained, in all material
respects, effective internal control over financial reporting as of October 31, 2010, based on
criteria established in Internal Control Integrated Framework issued by the Committee of
Sponsoring Organizations of the Treadway Commission.
/s/ KPMG LLP
Hartford, Connecticut
January 14, 2011
75
FUELCELL ENERGY, INC.
Consolidated Balance Sheets
(Amounts in thousands, except share and per share amounts)
|
|
|
|
|
|
|
|
|
|
|
October 31, |
|
|
October 31, |
|
|
|
2010 |
|
|
2009 |
|
ASSETS |
|
|
|
|
|
|
|
|
Current assets: |
|
|
|
|
|
|
|
|
Cash and cash equivalents |
|
$ |
20,467 |
|
|
$ |
57,823 |
|
Investments: U.S. treasury securities |
|
|
25,019 |
|
|
|
7,004 |
|
Accounts receivable, net of allowance for doubtful
accounts of $393 and $19, respectively |
|
|
18,066 |
|
|
|
22,920 |
|
Inventories, net |
|
|
33,404 |
|
|
|
25,433 |
|
Other current assets |
|
|
5,253 |
|
|
|
6,499 |
|
|
|
|
|
|
|
|
Total current assets |
|
|
102,209 |
|
|
|
119,679 |
|
|
|
|
|
|
|
|
|
|
Property, plant and equipment, net |
|
|
26,679 |
|
|
|
32,394 |
|
|
|
|
|
|
|
|
|
|
Investments: U.S. treasury securities |
|
|
9,071 |
|
|
|
|
|
Investment and loan to affiliate |
|
|
9,837 |
|
|
|
10,064 |
|
Other assets, net |
|
|
2,733 |
|
|
|
551 |
|
|
|
|
|
|
|
|
Total assets |
|
$ |
150,529 |
|
|
$ |
162,688 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
LIABILITIES AND EQUITY |
|
|
|
|
|
|
|
|
Current liabilities: |
|
|
|
|
|
|
|
|
Current portion of long-term debt and other liabilities |
|
$ |
976 |
|
|
$ |
997 |
|
Accounts payable |
|
|
10,267 |
|
|
|
8,484 |
|
Accounts payable due to affiliate |
|
|
575 |
|
|
|
1,584 |
|
Accrued liabilities |
|
|
16,721 |
|
|
|
13,808 |
|
Deferred revenue, royalty income and customer deposits |
|
|
25,499 |
|
|
|
17,013 |
|
|
|
|
|
|
|
|
Total current liabilities |
|
|
54,038 |
|
|
|
41,886 |
|
|
|
|
|
|
|
|
|
|
Long-term deferred revenue and royalty income |
|
|
8,042 |
|
|
|
10,124 |
|
|
|
|
|
|
|
|
|
|
Long-term debt and other liabilities |
|
|
4,056 |
|
|
|
4,410 |
|
|
|
|
|
|
|
|
Total liabilities |
|
|
66,136 |
|
|
|
56,420 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Redeemable minority interest |
|
|
16,849 |
|
|
|
14,976 |
|
Redeemable convertible preferred stock (liquidation preference of $64,020
at October 31, 2010 and $64,120 at October 31, 2009) |
|
|
59,857 |
|
|
|
59,950 |
|
Commitments and contingencies (Note 16) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Equity: |
|
|
|
|
|
|
|
|
Stockholders equity |
|
|
|
|
|
|
|
|
Common stock, ($.0001 par value); 150,000,000 shares authorized; 112,965,725
and
84,387,741 shares issued and outstanding at October 31, 2010 and 2009 respectively) |
|
|
11 |
|
|
|
8 |
|
Additional paid-in capital |
|
|
663,951 |
|
|
|
631,296 |
|
Accumulated deficit |
|
|
(655,623 |
) |
|
|
(599,960 |
) |
Accumulated other comprehensive income (loss) |
|
|
11 |
|
|
|
(2 |
) |
Treasury stock, Common, at cost (5,679 shares at October 31, 2010
and 2009, respectively) |
|
|
(53 |
) |
|
|
(53 |
) |
Deferred compensation |
|
|
53 |
|
|
|
53 |
|
|
|
|
|
|
|
|
Total stockholders equity |
|
|
8,350 |
|
|
|
31,342 |
|
Noncontrolling interest in subsidiaries |
|
|
(663 |
) |
|
|
|
|
|
|
|
|
|
|
|
Total equity |
|
|
7,687 |
|
|
|
31,342 |
|
|
|
|
|
|
|
|
Total liabilities and equity |
|
$ |
150,529 |
|
|
$ |
162,688 |
|
|
|
|
|
|
|
|
See accompanying notes to consolidated financial statements.
76
FUELCELL ENERGY, INC.
Consolidated Statements of Operations
For the Years Ended October 31, 2010, 2009, and 2008
(Amounts in thousands, except share and per share amounts)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended |
|
|
|
October 31, |
|
|
October 31, |
|
|
October 31, |
|
|
|
2010 |
|
|
2009 |
|
|
2008 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Revenues |
|
|
|
|
|
|
|
|
|
|
|
|
Product sales and revenues |
|
$ |
59,226 |
|
|
$ |
73,804 |
|
|
$ |
82,748 |
|
Research and development contracts |
|
|
10,551 |
|
|
|
14,212 |
|
|
|
17,987 |
|
|
|
|
|
|
|
|
|
|
|
Total revenues |
|
|
69,777 |
|
|
|
88,016 |
|
|
|
100,735 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Costs and expenses |
|
|
|
|
|
|
|
|
|
|
|
|
Cost of product sales and revenues |
|
|
78,060 |
|
|
|
107,033 |
|
|
|
134,038 |
|
Cost of research and development contracts |
|
|
10,370 |
|
|
|
10,994 |
|
|
|
16,059 |
|
Administrative and selling expenses |
|
|
17,150 |
|
|
|
17,194 |
|
|
|
19,968 |
|
Research and development costs |
|
|
18,562 |
|
|
|
19,160 |
|
|
|
23,471 |
|
|
|
|
|
|
|
|
|
|
|
Total costs and expenses |
|
|
124,142 |
|
|
|
154,381 |
|
|
|
193,536 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss from operations |
|
|
(54,365 |
) |
|
|
(66,365 |
) |
|
|
(92,801 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Interest expense |
|
|
(127 |
) |
|
|
(265 |
) |
|
|
(100 |
) |
Loss from equity investments |
|
|
(730 |
) |
|
|
(812 |
) |
|
|
(1,867 |
) |
Interest and other income, net |
|
|
1,354 |
|
|
|
860 |
|
|
|
3,268 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss before redeemable minority interest |
|
|
(53,868 |
) |
|
|
(66,582 |
) |
|
|
(91,500 |
) |
Redeemable minority interest |
|
|
(2,367 |
) |
|
|
(2,092 |
) |
|
|
(1,857 |
) |
|
|
|
|
|
|
|
|
|
|
Loss before provision for income tax |
|
|
(56,235 |
) |
|
|
(68,674 |
) |
|
|
(93,357 |
) |
Provision for income tax |
|
|
(91 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss |
|
|
(56,326 |
) |
|
|
(68,674 |
) |
|
|
(93,357 |
) |
Net loss attributable to noncontrolling interest |
|
|
663 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss attributable to FuelCell Energy, Inc. |
|
|
(55,663 |
) |
|
|
(68,674 |
) |
|
|
(93,357 |
) |
Preferred stock dividends |
|
|
(3,201 |
) |
|
|
(3,208 |
) |
|
|
(3,208 |
) |
|
|
|
|
|
|
|
|
|
|
Net loss to common shareholders |
|
$ |
(58,864 |
) |
|
$ |
(71,882 |
) |
|
$ |
(96,565 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss to common shareholders |
|
|
|
|
|
|
|
|
|
|
|
|
Basic |
|
$ |
(0.63 |
) |
|
$ |
(0.99 |
) |
|
$ |
(1.41 |
) |
Diluted |
|
$ |
(0.63 |
) |
|
$ |
(0.99 |
) |
|
$ |
(1.41 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Weighted average shares outstanding |
|
|
|
|
|
|
|
|
|
|
|
|
Basic |
|
|
93,925,863 |
|
|
|
72,392,928 |
|
|
|
68,570,689 |
|
Diluted |
|
|
93,925,863 |
|
|
|
72,392,928 |
|
|
|
68,570,689 |
|
See accompanying notes to consolidated financial statements.
77
FUELCELL ENERGY, INC.
Consolidated Statements of Changes in Equity
For the Years Ended October 31, 2010, 2009, and 2008
(Amounts in thousands, except share and per share amounts)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Other |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Additional |
|
|
|
|
|
|
Comprehensive |
|
|
|
|
|
|
|
|
|
|
Noncontrolling |
|
|
|
|
|
|
Common Stock |
|
|
Paid-in |
|
|
Accumulated |
|
|
Income |
|
|
Treasury |
|
|
Deferred |
|
|
Interest in |
|
|
Total |
|
|
|
Shares |
|
|
Amount |
|
|
Capital |
|
|
Deficit |
|
|
(Loss) |
|
|
Stock |
|
|
Compensation |
|
|
subsidiaries |
|
|
Equity |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance, October 31, 2007 |
|
|
68,085,059 |
|
|
$ |
7 |
|
|
$ |
571,944 |
|
|
$ |
(437,929 |
) |
|
$ |
|
|
|
$ |
(126 |
) |
|
$ |
126 |
|
|
$ |
|
|
|
$ |
134,022 |
|
Sale of common stock |
|
|
180,000 |
|
|
|
|
|
|
|
1,689 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
1,689 |
|
Share based compensation |
|
|
|
|
|
|
|
|
|
|
5,529 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
5,529 |
|
Stock issued under benefit plans |
|
|
514,086 |
|
|
|
|
|
|
|
2,383 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2,383 |
|
Preferred dividends Series B |
|
|
|
|
|
|
|
|
|
|
(3,208 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(3,208 |
) |
Deferred compensation |
|
|
3,301 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
36 |
|
|
|
(36 |
) |
|
|
|
|
|
|
|
|
Net loss |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(93,357 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(93,357 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance, October 31, 2008 |
|
|
68,782,446 |
|
|
$ |
7 |
|
|
$ |
578,337 |
|
|
$ |
(531,286 |
) |
|
$ |
|
|
|
$ |
(90 |
) |
|
$ |
90 |
|
|
$ |
|
|
|
$ |
47,058 |
|
Sale of common stock |
|
|
14,450,118 |
|
|
|
1 |
|
|
|
50,193 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
50,194 |
|
Share based compensation |
|
|
|
|
|
|
|
|
|
|
4,815 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
4,815 |
|
Stock issued under benefit plans |
|
|
1,151,875 |
|
|
|
|
|
|
|
1,307 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
1,307 |
|
Preferred dividends Series B |
|
|
|
|
|
|
|
|
|
|
(3,208 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(3,208 |
) |
Change in fair value of warrants |
|
|
|
|
|
|
|
|
|
|
(148 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(148 |
) |
Deferred compensation |
|
|
3,302 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
37 |
|
|
|
(37 |
) |
|
|
|
|
|
|
|
|
Effect of foreign currency
translation |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(2 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(2 |
) |
Net loss |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(68,674 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(68,674 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance, October 31, 2009 |
|
|
84,387,741 |
|
|
$ |
8 |
|
|
$ |
631,296 |
|
|
$ |
(599,960 |
) |
|
$ |
(2 |
) |
|
$ |
(53 |
) |
|
$ |
53 |
|
|
$ |
|
|
|
$ |
31,342 |
|
Sale of common stock |
|
|
27,600,000 |
|
|
|
3 |
|
|
|
32,077 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
32,080 |
|
Share based compensation |
|
|
|
|
|
|
|
|
|
|
2,965 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2,965 |
|
Conversion of Series B preferred
stock to common stock, net of
original issuance costs |
|
|
8,510 |
|
|
|
|
|
|
|
93 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
93 |
|
Stock issued under benefit plans |
|
|
969,474 |
|
|
|
|
|
|
|
721 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
721 |
|
Preferred dividends Series B |
|
|
|
|
|
|
|
|
|
|
(3,201 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(3,201 |
) |
Noncontrolling interest in
subsidiaries |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(663 |
) |
|
|
(663 |
) |
Effect of foreign currency
translation |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
13 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
13 |
|
Net loss |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(55,663 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(55,663 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance, October 31, 2010 |
|
|
112,965,725 |
|
|
$ |
11 |
|
|
$ |
663,951 |
|
|
$ |
(655,623 |
) |
|
$ |
11 |
|
|
$ |
(53 |
) |
|
$ |
53 |
|
|
$ |
(663 |
) |
|
$ |
7,687 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
See accompanying notes to consolidated financial statements.
78
FUELCELL ENERGY, INC.
Consolidated Statements of Cash Flows
For the Years Ended October 31, 2010, 2009, and 2008
(Amounts in thousands, except share and per share amounts)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended October 31, |
|
|
|
2010 |
|
|
2009 |
|
|
2008 |
|
Cash flows from operating activities: |
|
|
|
|
|
|
|
|
|
|
|
|
Net loss |
|
$ |
(56,326 |
) |
|
$ |
(68,674 |
) |
|
$ |
(93,357 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Adjustments to reconcile net loss to net cash used
in operating activities: |
|
|
|
|
|
|
|
|
|
|
|
|
Stock-based compensation |
|
|
2,965 |
|
|
|
4,815 |
|
|
|
5,529 |
|
Loss in equity investments |
|
|
730 |
|
|
|
812 |
|
|
|
1,867 |
|
Redeemable minority interest |
|
|
2,367 |
|
|
|
2,092 |
|
|
|
1,857 |
|
Interest receivable on loan to affiliate |
|
|
(155 |
) |
|
|
(141 |
) |
|
|
(162 |
) |
Asset impairment |
|
|
765 |
|
|
|
|
|
|
|
179 |
|
Loss (gain) on derivatives |
|
|
95 |
|
|
|
330 |
|
|
|
(99 |
) |
Depreciation and amortization |
|
|
7,438 |
|
|
|
8,591 |
|
|
|
8,801 |
|
Amortization of bond premium |
|
|
91 |
|
|
|
836 |
|
|
|
607 |
|
(Recovery) provision for doubtful accounts |
|
|
374 |
|
|
|
(32 |
) |
|
|
(13 |
) |
(Increase) decrease in operating assets: |
|
|
|
|
|
|
|
|
|
|
|
|
Accounts receivable |
|
|
4,480 |
|
|
|
(6,792 |
) |
|
|
(6,020 |
) |
Inventories |
|
|
(7,971 |
) |
|
|
(910 |
) |
|
|
5,058 |
|
Other assets |
|
|
(785 |
) |
|
|
2,402 |
|
|
|
(1,462 |
) |
Increase (decrease) in operating liabilities: |
|
|
|
|
|
|
|
|
|
|
|
|
Accounts payable |
|
|
774 |
|
|
|
(7,050 |
) |
|
|
4,614 |
|
Accrued liabilities |
|
|
3,762 |
|
|
|
3,786 |
|
|
|
3,824 |
|
Deferred revenue and customer deposits |
|
|
6,404 |
|
|
|
(5,268 |
) |
|
|
7,370 |
|
|
|
|
|
|
|
|
|
|
|
Net cash used in operating activities |
|
|
(34,992 |
) |
|
|
(65,203 |
) |
|
|
(61,407 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cash flows from investing activities: |
|
|
|
|
|
|
|
|
|
|
|
|
Capital expenditures for property and equipment |
|
|
(2,481 |
) |
|
|
(2,588 |
) |
|
|
(7,368 |
) |
Convertible loan to affiliate |
|
|
(600 |
) |
|
|
(600 |
) |
|
|
|
|
Treasury notes matured |
|
|
32,500 |
|
|
|
41,000 |
|
|
|
79,100 |
|
Treasury notes purchased |
|
|
(59,677 |
) |
|
|
|
|
|
|
(67,913 |
) |
|
|
|
|
|
|
|
|
|
|
Net cash (used in) provided by investing activities |
|
|
(30,258 |
) |
|
|
37,812 |
|
|
|
3,819 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cash flows from financing activities: |
|
|
|
|
|
|
|
|
|
|
|
|
Repayments of debt |
|
|
(377 |
) |
|
|
(237 |
) |
|
|
(449 |
) |
Proceeds from debt |
|
|
|
|
|
|
436 |
|
|
|
3,564 |
|
Net proceeds from sale of common stock |
|
|
32,104 |
|
|
|
50,332 |
|
|
|
2,091 |
|
Payment of preferred dividends |
|
|
(3,695 |
) |
|
|
(3,631 |
) |
|
|
(3,642 |
) |
Common stock issued for option and stock purchase plans |
|
|
(151 |
) |
|
|
273 |
|
|
|
1,070 |
|
|
|
|
|
|
|
|
|
|
|
Net cash provided by financing activities |
|
|
27,881 |
|
|
|
47,173 |
|
|
|
2,634 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Effect on cash from changes in foreign currency rates |
|
|
13 |
|
|
|
(2 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net (decrease) increase in cash and cash equivalents |
|
|
(37,356 |
) |
|
|
19,780 |
|
|
|
(54,954 |
) |
Cash and cash equivalents at beginning of period |
|
|
57,823 |
|
|
|
38,043 |
|
|
|
92,997 |
|
|
|
|
|
|
|
|
|
|
|
Cash and cash equivalents at end of period |
|
$ |
20,467 |
|
|
$ |
57,823 |
|
|
$ |
38,043 |
|
|
|
|
|
|
|
|
|
|
|
See accompanying notes to the consolidated financial statements.
79
Note 1. Nature of Business and Significant Accounting Policies
Nature of Business
FuelCell Energy, Inc. and subsidiaries (the Company, we, us, our) are engaged in the
development and manufacture of high temperature fuel cells for clean electric power generation.
Our Direct FuelCell power plants produce reliable, secure and environmentally friendly 24/7 base
load electricity for commercial, industrial, government and utility customers. We have
commercialized our stationary fuel cells and are beginning the development of planar solid oxide
fuel cell and other fuel cell technology. We expect to incur losses as we continue to participate
in government cost share programs, sell products at prices lower than our costs, and invest in our
cost reduction initiatives.
The consolidated financial statements include our accounts and those of our subsidiaries, including
FuelCell Energy, Ltd. (FCE Ltd.), our Canadian subsidiary; Bridgeport Fuel Cell Park, LLC
(BFCP), DFC-ERG Milford, LLC and DFC-ERG Connecticut, LLC, which were formed for the purpose of
developing projects within Connecticut; and FCE Korea Ltd., which was formed to facilitate our
business operations in South Korea. Alliance Monterrey, LLC; Alliance Chico, LLC; Alliance Star
Energy, LLC; and Alliance TST Energy, LLC, (collectively, the Alliance Entities) are joint
ventures with Alliance Power, Inc. (Alliance) established to construct fuel cell power plants and
sell power under power purchase agreements (PPA). We have an 80 percent interest in each entity
and accordingly, the financial results of the Alliance Entities are consolidated with our financial
results. All intercompany accounts and transactions have been eliminated.
Significant Accounting Policies
Cash and Cash Equivalents
Cash equivalents consist primarily of investments in money market funds and U.S. Treasury
securities with original maturities averaging three months or less at date of acquisition. We
place our temporary cash investments with high credit quality financial institutions. We have
pledged approximately $9.0 million of our cash and cash equivalents as collateral against letters
of credit, banking requirements and customer contracts. At October 31, 2010 and 2009, we had
outstanding letters of credit of $7.3 million and $0.6 million, respectively.
Investments
Investments consist of U.S. Treasury securities with original maturities of greater than three
months at the date of acquisition. The notes are classified as held-to-maturity since we have the
ability and intention to hold them until maturity. The notes are carried at amortized cost, which
is par value, plus or minus unamortized premium or discount. We classify notes with remaining
maturities of one year or less as current assets and notes with remaining maturities greater than
one year as non-current assets.
Inventories and Advance Payments to Vendors
Inventories consist principally of raw materials and work-in-process and are stated at the lower of
cost or market. In certain circumstances, we will make advance payments to vendors for future
inventory deliveries. These advance payments (net of related reserves) are recorded as other
current assets on the consolidated balance sheets.
Prior to November 1, 2009, we provided for a lower of cost or market (LCM) reserve to the cost
basis of inventory at the time of purchase as our products were historically sold below cost.
During the second half of 2009, we began production of our newest megawatt-class power plants and
modules. The manufactured cost per kilowatt of these products is lower than previous models due to
a 17 percent power increase and lower component and raw materials cost and are expected to be gross
margin positive on a unit by unit basis. As a
result, beginning in fiscal 2010, we revised our method of estimating contract losses and no longer
provide for an LCM reserve on new inventory purchased.
80
As of October 31, 2010 and October 31, 2009, the LCM adjustment to the cost basis of inventory and
advance payments to vendors was $5.0 million and $9.5 million, respectively, which equates to a
reduction of 12 and 25 percent, respectively, of the gross inventory and advance payments to
vendors value. As inventory is utilized in finished products and sold or used to service LTSAs the
Company expects the LCM reserve to continue to decline.
Property, Plant and Equipment
Property, plant and equipment are stated at cost, less accumulated depreciation provided on the
straight-line method over the estimated useful lives of the respective assets. Leasehold
improvements are amortized on the straight-line method over the shorter of the estimated useful
lives of the assets or the term of the lease. When property is sold or otherwise disposed of, the
cost and related accumulated depreciation are removed from the accounts and any resulting gain or
loss is reflected in operations for the period.
Intellectual Property
Intellectual property, including internally generated patents and know-how, is carried at no value.
Impairment of Long Lived Assets
Long-lived assets are reviewed for impairment whenever events or changes in circumstances indicate
that the carrying amount of an asset group may not be recoverable. If events or changes in
circumstances indicate that the carrying amount of an asset group may not be recoverable, we
compare the carrying amount of the asset group to future undiscounted net cash flows, excluding
interest costs, expected to be generated by the asset group and their ultimate disposition. If the
sum of the undiscounted cash flows is less than the carrying value, the impairment to be recognized
is measured by the amount by which the carrying amount of the asset group exceeds the fair value of
the asset group. Assets to be disposed of are reported at the lower of the carrying amount or fair
value, less costs to sell.
Revenue Recognition
We earn revenue from (i) the sale and installation of fuel cell power plants and modules (ii) sale
of component part kits and spare parts to customers, (iii) site engineering and construction
services (iv) providing services under long-term service agreements (LTSA), (v) the sale of
electricity under power purchase agreements (PPA) as well as incentive revenue from the sale of
electricity under PPAs, and (vi) customer-sponsored research and development projects. Our revenue
is primarily generated from customers located throughout the U.S. and Asia and from agencies of the
U.S. government. Revenue from customer-sponsored research and development projects is recorded as
research and development contracts revenue and all other revenues are recorded as product sales and
revenues in the consolidated statements of operations.
Revenue from sales of our DFC power plants and modules are recognized under the percentage of
completion method of accounting. Revenues are recognized proportionally as costs are incurred and
assigned to a customer contract by comparing total expected costs for each contract to the total
contract value. Prior to fiscal 2010, we did not provide for a contract loss reserve on product
sales contracts as products were in their early stages of development and market acceptance, and
the total costs and timing of production for product sales contracts as well as installation and
commissioning of these units could not be reasonably estimated. However, upon procurement of
inventory for fulfillment of a product sales contract, the Company recorded such inventory at the
lower of cost or market. As a result of a more consistent production rate and predictable timing
for fulfillment of product sales contracts and more installation and commissioning experience for
our major product lines, effective November 1, 2009 a contract loss reserve on product sales
contracts is recognized at the time we become aware that estimated total costs are expected to
exceed the contract sales price. As of October 31, 2010, the estimated loss reserve for contracts
in backlog totaled approximately $0.6
million. Actual results could vary from initial estimates and reserve estimates will be updated as
we gain further manufacturing and operating experience.
81
Revenue from component part kits and spare parts sales is recognized upon shipment and title
transfer under the terms of the customer contract.
Revenue from LTSA contracts for power plants with our 5-year stack design is earned ratably over
the term of the contract by performing routine monitoring and maintenance and by meeting a certain
level of power output. For our legacy LTSA contracts on power plants with our older 3-year stack
design, a portion of the contract value related to the stack replacement has been deferred. Upon
stack replacement, revenue is recognized ratably over the remaining contract term. Revenue related
to routine monitoring and maintenance under legacy contracts is recognized ratably over the full
term of the contract.
Revenue from the sale of electricity is recognized as electricity is provided to the customer.
Incentive revenue is recognized ratably over the term of the PPA. Site engineering and construction
services revenue is recognized on percentage of completion as costs are incurred.
Revenue from research and development contracts is recognized proportionally as costs are incurred
and compared to the estimated total research and development costs for each contract. Revenue from
government funded research, development and demonstration programs are generally multi-year,
cost-reimbursement and/or cost-shared type contracts or cooperative agreements. We are reimbursed
for reasonable and allocable costs up to the reimbursement limits set by the contract or
cooperative agreement, and on certain contracts we are reimbursed only a portion of the costs
incurred. While government research and development contracts may extend for many years, funding
is often provided incrementally on a year-by-year basis if contract terms are met and Congress has
authorized the funds.
Warranty and Service Expense Recognition
We warranty our products for a specific period of time against manufacturing or performance
defects. Our warranty is limited to a term generally 15 months after shipment or 12 months after
installation of our products. We reserve for estimated future warranty costs based on historical
experience. We also provide for a specific reserve if a there is a known issue requiring repair
during the warranty period. Given our limited operating experience, particularly for newer product
designs, actual results could vary from initial estimates. Estimates used to record warranty
reserves are updated as we gain further operating experience. As of October 31, 2010 and October
31, 2009, the warranty reserve, which is classified in accrued liabilities on the consolidated
balance sheet totaled $0.7 million and $0.5 million, respectively.
In addition to the standard product warranty, we have entered into LTSA contracts with certain
customers to provide monitoring, maintenance and repair services for fuel cell power plants ranging
from one to 20 years. Our standard service agreement term is five years. Under the terms of our
LTSA, the power plant must meet a minimum operating output during the term. If minimum output
falls below the contract requirement, we may be subject to performance penalties or may be required
to repair or replace the customers fuel cell stack. The Company has provided for a reserve for
performance guarantees, which based on historical fleet performance totaled $1.2 million and $0.9
million as of October 31, 2010 and 2009, respectively.
For our legacy LTSA contracts on power plants with our older 3-year stack design, the Company has
accrued a reserve based on estimates of future stack replacement and service costs in excess of the
contract value. We expect the replacement of older stacks produced prior to the five-year stack
design will continue into mid-2012. Reserve estimates for future costs associated with maintaining
legacy service agreements are determined by a number of factors including the estimated life of the
stack, used replacement stacks available, our limit of liability on service agreements and future
operating plans for the power plant. Our reserve estimates include cost assumptions based on what
we anticipate the service requirements will be to fulfill obligations on a contract by contract
basis, which in many cases is in excess of our contractual limit of liability under LTSAs which is
limited to the amount of service fees payable under the contract. As of October 31, 2010, our
reserve on LTSA contracts totaled $6.6 million compared to $6.0 million as of
October 31, 2009.
82
LTSAs for power plants that have our five-year stack design are not expected to require a stack
change to continue to meet minimum operating levels during the initial five-year term of the
contract, although we have limited operating experience with these products. Stack replacements for
new agreements which include the five-year stack design are expected to only be required upon
renewal of the service agreement by the customer.
At the end of our LTSA contracts, customers are expected to either renew the contract or we
anticipate that the stack module or the entire power plant will be returned to the Company as the
plant is no longer being monitored or having routine service performed. In situations where the
customer agrees at the time of a restack to return the stack to the Company at the end of the LTSA
term, the cost of the stack is recorded as a long-term asset and depreciated over its expected
life. If the Company does not obtain rights to title from the customer, the cost of the stack is
expensed at the time of restack. As of October 31, 2010, total stack value recorded as a long-term
asset was $2.0 million, net of $0.1 million of accumulated
depreciation. This balance is expected to increase over time as stack replacements occur.
Deferred Revenue, Royalty Income and Customer Deposits
In February 2007, we entered into a 10-year manufacturing and distribution agreement with POSCO
Power (POSCO). Under the terms of this agreement, POSCO will manufacture balance of plant
(BOP) in South Korea using its design, procurement and manufacturing expertise. Under the terms
of the agreement, we will receive a 4.1 percent royalty on sales of BOP made by POSCO, subject to
minimum royalties. Minimum annual royalties under this agreement and recorded were $0.3 and $0.2 million for the years ended October
31, 2010 and 2009, respectively.
In October 2009, we entered into a 10-year Stack Technology Transfer and License Agreement (the
2009 License Agreement) with POSCO allowing it to produce fuel cell stack modules from cells and
components provided by us. These fuel cell modules will be combined with BOP manufactured in South
Korea to complete electricity-producing fuel cell power plants for sale in South Korea. The 2009
License Agreement provides for an ongoing royalty, initially set at 4.1 percent of the revenues
generated from sales of fuel cell stack modules manufactured and sourced by POSCO.
In connection with the 2009 License Agreement, we received an upfront license fee of $10.0 million.
This amount has been deferred and will be recognized as revenue ratably over the term of the 2009
License Agreement.
In addition, we receive payments from customers upon the acceptance of a purchase order and when
contractual milestones are reached. These payments may be deferred based on the nature of the
payment and status of the specific project. Deferred revenue is recognized as revenue in accordance
with our revenue recognition policies summarized above.
Warrant Value Recognition
Warrants have been issued as sales incentives to certain of our business partners. These warrants
vested if orders from our business partners exceeded stipulated levels. If warrants vested, or if
management estimated that it was probable that warrants would vest, a proportional amount of the
fair value of the warrants was capitalized and subsequently recorded as a sales discount when the
related revenue was recognized. There were no material amounts charged to sales discounts for the
years ended October 31, 2010, 2009 and 2008. As of October 31, 2010 and 2009, there are no
remaining warrants outstanding.
83
Research and Development Costs
We perform both customer-sponsored research and development projects based on contractual agreement
with customers and company-sponsored research and development projects. Costs incurred for
customer-sponsored projects include manufacturing and engineering labor, applicable overhead
expenses, materials to build and test prototype units and other costs associated with
customer-sponsored research and development contracts. These costs are recorded as cost of
research and development contracts in the consolidated statements of operations.
Costs incurred for company-sponsored research and development projects consist primarily of labor,
overhead, materials to build and test prototype units and consulting fees. These costs are
recorded as research and development expenses in the consolidated statements of operations.
Share-Based Compensation
We account for stock options awarded to employees and non-employee directors under the fair value
method of accounting using the Black-Scholes valuation model to estimate fair value at the grant
date. The model requires us to make estimates and assumptions regarding the expected life of the
option, the risk-free interest rate, the expected volatility of our common stock price and the
expected dividend yield. The fair value of stock options is amortized to expense over the vesting
period, generally four years. Refer to Note 13 for additional information.
Income Taxes
Income taxes are accounted for under the liability method. Deferred tax assets and liabilities are
determined based on net operating loss (NOL) carryforwards, research and development credit
carryforwards, and differences between financial reporting and income tax bases of assets and
liabilities. Deferred tax assets and liabilities are measured using enacted tax rates and laws
expected to be in effect when the differences are expected to reverse. The effect on deferred tax
assets and liabilities of a change in tax rates is recognized in income in the period that includes
the enactment date. A valuation allowance is recorded against deferred tax assets if it is
unlikely that some or all of the deferred tax assets will be realized.
As of November 1, 2007, we adopted guidance for how a company should recognize, measure, present,
and disclose in its financial statements uncertain tax positions that the company has taken or
expects to take on a tax return (including a decision whether to file or not file a return in a
particular jurisdiction). The companys financial statements reflect expected future tax
consequences of such positions presuming the taxing authorities full knowledge of the position and
all relevant facts.
Concentrations
We contract with a small number of customers for the sale of our products and for research and
development contracts. For the fiscal years ended October 31, 2010, 2009 and 2008, our top three
customers accounted for 83 percent, 80 percent and 62 percent, respectively, of our total annual
consolidated revenue.
For the fiscal years ended October 31, 2010, 2009 and 2008, our top three customers, POSCO, which
is a related party and owns approximately 10 percent of the outstanding common shares of the
Company, the U.S. government (primarily the Department of Energy) and Pacific Gas and Electric,
accounted for 83 percent, 80 percent and 63 percent, respectively of our total annual consolidated
revenue. Our largest strategic partner, POSCO, accounted for 58 percent, 64 percent and 46 percent
of total revenues, the U.S. government accounted for 15 percent, 16 percent and 17 percent of total
revenues and Pacific Gas and Electric accounted for 10 percent of total revenues for the fiscal
year ended October 31, 2010 and there was no revenue from Pacific Gas and Electric in 2009 or 2008.
84
There can be no assurance that we will continue to achieve historical levels of sales of our
products to our largest customers. Even though our customer base is expected to increase and our
revenue streams to diversify, a substantial portion of net revenues could continue to depend on
sales to a limited number of
customers. Our agreements with these customers may be cancelled if we fail to meet certain product
specifications or materially breach the agreement, and our customers may seek to renegotiate the
terms of current agreements or renewals. The loss of, or a reduction in sales to, one or more of
our larger customers could have a material adverse affect on our business, financial condition and
results of operations.
Derivatives
We do not use derivatives for trading or speculative purposes. Derivative instruments consist of
our warrants to purchase additional shares of common stock of Versa Power Systems, Inc. (Versa)
and embedded derivatives in our Series 1 Preferred Shares. We account for these derivatives using
the fair-value method with changes in the underlying fair value recorded to earnings. Refer to
Notes 2 and 11 for additional information.
Use of Estimates
The preparation of financial statements and related disclosures in conformity with accounting
principles generally accepted in the U.S. requires management to make estimates and assumptions
that affect the reported amounts of assets, liabilities, revenues and expenses and the disclosure
of contingent assets and liabilities. Actual results could differ from those estimates. Estimates
are used in accounting for, among other things, revenue recognition, excess, slow-moving and
obsolete inventories, product warranty costs, LTSA reserves, allowance for uncollectible
receivables, depreciation and amortization, impairment of assets, taxes, and contingencies.
Estimates and assumptions are reviewed periodically, and the effects of revisions are reflected in
the consolidated financial statements in the period they are determined to be necessary.
Comprehensive Income (Loss)
Comprehensive loss of $55.7 million, $68.7 million and $93.4 million
includes net loss to common shareholders of $55.7 million, $68.7 million
and $93.4 million (as reported before
preferred dividends) and foreign currency translation adjustments of $13.0 thousand, $2.0 thousand and $0 for the years ended October 31, 2010, 2009
and 2008, respectively, which are included as a
component of stockholders equity in the consolidated balance sheets.
Foreign Currency Translation
The translation of FuelCell Korea Ltds financial statements results in translation gains or
losses, which are recorded in accumulated other comprehensive income (loss) within stockholders
equity.
Our Canadian subsidiary, FCE Ltd., is financially and operationally integrated and therefore the
temporal method of translation of foreign currencies is followed. The functional currency is U.S.
dollars. We are subject to foreign currency transaction gains and losses as certain invoices are
denominated in Canadian dollars. We recognized a loss of $0.01 million, a loss of $0.2 million, a
loss of $0.3 million for the years ended October 31, 2010, 2009 and 2008, respectively. These
amounts have been classified as interest and other income, net in the consolidated statements of
operations.
Subsequent Events
We have evaluated subsequent events and are not aware of any significant events that occurred
subsequent to the balance sheet date but prior to the filing of this Form 10-K with the SEC that
would have a material impact on our consolidated financial statements.
85
Liquidity
We anticipate that our existing capital resources, together with anticipated revenues and cash
flows, will be adequate to satisfy our financial requirements and agreements through at least the
next 12 months. As a result of product cost reductions, we believe sales volume of 75 MW to 125 MW
will drive the Company to profitability with the lower end of the range reflecting a sales mix
oriented towards complete power plants and the upper end of the range oriented towards fuel cell
components. Our future liquidity will be dependent on obtaining the order volumes and cost
reductions on our fuel cell products necessary to achieve profitable operations. We may also raise
capital through additional equity offerings; however, there can be no assurance
that we will be able to obtain additional financing in the future. If we are unable to raise
additional capital, our growth potential may be adversely affected and we may have to modify our
plans.
Recently Adopted Accounting Pronouncements
In April 2008, the Financial Accounting Standards Board (FASB) issued accounting guidance that
amends the factors that should be considered in developing renewal or extension assumptions used to
determine the useful life of a recognized definite-lived intangible asset. In developing
assumptions about renewal or extension options used to determine the useful life of a
definite-lived intangible asset, a company needs to consider its own historical experience adjusted
for company-specific factors. In the absence of that experience, the company shall consider the
assumptions that market participants would use about renewal or extension options. The new guidance
was effective for the first quarter of fiscal 2010. We currently do not have any intangible assets
recorded in our consolidated balance sheets; therefore, the impact of this guidance on our
consolidated financial statements will be determined when and if we acquire definite-lived
intangible assets.
In December 2007, the FASB issued new guidance that requires noncontrolling interests (formerly
minority interests) in a subsidiary be reported as equity in the consolidated financial
statements. Consolidated net income should include the net income for both the parent and the
noncontrolling interest with disclosure of both amounts in the consolidated statements of
operations. The calculation of earnings per share would continue to be based on income amounts
attributable to the parent. This guidance became effective for the quarter ended January 31, 2010
and changed the accounting for and reporting of noncontrolling interests in our subsidiaries.
In December 2007, the FASB issued revised accounting guidance for business combinations that
requires an acquirer to measure the identifiable assets acquired, the liabilities assumed and any
noncontrolling interest in the acquiree at their fair values on the acquisition date, with goodwill
being the excess value over the net identifiable assets acquired. The guidance also requires that
certain other assets and liabilities related to the acquisition, such as contingencies and research
and development, be recorded at fair value. The new guidance was effective for the first quarter of
fiscal 2010. The potential impact of this revised guidance on our consolidated financial
statements will be based upon future business combinations, if any.
86
Recent Accounting Guidance Not Yet Effective
In April 2010, the FASB provided guidance on defining a milestone and determining when it may be
appropriate to apply the milestone method of revenue recognition for research or development
transactions. Research or development arrangements frequently include payment provisions whereby a
portion or all of the consideration is contingent upon the achievement of milestone events. An
entity may only recognize consideration that is contingent upon the achievement of a milestone in
its entirety in the period the milestone is achieved only if the milestone meets certain criteria.
This guidance is effective prospectively for milestones achieved in fiscal years beginning on or
after June 15, 2010 (November 1, 2010 for the Company). While we are still analyzing the potential
impact of this guidance, we believe that our current practices are consistent with the guidance
and, accordingly, we do not expect the adoption of this guidance will have a material impact on our
financial statements.
In January 2010, the FASB issued guidance that requires new disclosures for fair value measurements
and provides clarification for existing disclosure requirements. This amended guidance require
disclosures about inputs and valuation techniques used to measure fair value as well as disclosures
about significant transfers in and out of Levels 1 and Levels 2 fair value measurements and
disclosures about the purchase, sale, issuance and settlement activity of Level 3 fair value
measurements. This guidance is effective for interim and annual reporting periods beginning after
December 15, 2009, except for disclosures about the purchase, sale, issuance and settlement
activity of Level 3 fair value measurements, which is effective for fiscal years beginning after
December 15, 2010. The Company was not impacted by the disclosures effective for interim periods
beginning after December 15, 2009 and we do not expect the remaining disclosures required after
December 15, 2010 upon adoption of this guidance will have a material impact on our financial
statements or disclosures.
In December 2009, the FASB issued revised guidance related to the consolidation of variable
interest entities (VIE). The revised guidance requires reporting entities to evaluate former
qualified special purpose entities for consolidation, changes the approach to determining a VIEs
primary beneficiary from a quantitative assessment to a qualitative assessment designed to identify
a controlling financial interest, and increases the frequency of required reassessments to
determine whether a company is the primary beneficiary of a VIE. It also clarifies, but does not
significantly change, the characteristics that identify a VIE. The guidance is effective as of the
beginning of a companys first fiscal year beginning after November 15, 2009 (November 1, 2010 for
the Company), and for subsequent interim and annual reporting periods. We do not expect this
guidance will have an impact on our financial statements.
In October 2009, the FASB issued guidance updating accounting standards for revenue recognition for
multiple-deliverable arrangements. The stated objective of the update was to address the
accounting for multiple-deliverable arrangements to enable vendors to account for products or
services separately rather than as a combined unit. The guidance provides amended methodologies
for separating consideration in multiple-deliverable arrangements and expands disclosure
requirements. The guidance will be effective prospectively for revenue arrangements entered into
or materially modified in fiscal years beginning on or after June 15, 2010 (November 1, 2010 for
the Company), with early adoption permitted. We do not expect this guidance will have an impact on
our financial statements or disclosures.
In June 2009, the FASB issued accounting guidance which requires a company to perform ongoing
reassessment of whether it is the primary beneficiary of a variable interest entity (VIE).
Specifically, the guidance modifies how a company determines when an entity that is insufficiently
capitalized or is not controlled through voting (or similar rights) should be consolidated. The
guidance clarifies that the determination of whether a company is required to consolidate a VIE is
based on, among other things, an entitys purpose and design and a companys ability to direct the
activities of the VIE that most significantly impact the VIEs economic performance. The guidance
requires an ongoing reassessment of whether a company is the primary beneficiary of a VIE and
enhanced disclosures of the companys involvement in VIEs and any significant changes in risk
exposure due to that involvement. The guidance will be effective for the first quarter of fiscal
2011. We do not expect this guidance will have an impact on our financial statements.
87
Note 2. Equity investments
Versa is one of our sub-contractors under the Department of Energys (DOE) large-scale hybrid
project to develop a coal-based, multi-megawatt solid oxide fuel cell (SOFC) based hybrid system.
Versa is a private company founded in 2001 that is developing advanced SOFC systems for various
stationary and mobile applications. We have a 39 percent ownership interest and account for Versa
under the equity method of accounting. We recognize our share of the losses as loss from equity
investments on the consolidated statements of operations.
In 2007, we loaned Versa $2.0 million in the form of a convertible note (the 2007 Convertible
Note), in 2009, we loaned Versa $0.6 million and in 2010 we loaned Versa $0.6 million, also in the
form of convertible notes (the 2010 Convertible Note, the 2009 Convertible Note and the 2007
Convertible Note, the Convertible Notes). The 2007 Convertible Note matures May 2017, the 2009
Convertible Note matures November 2018 and the 2010 Convertible Note matures April 2020, unless
certain prepayment events occur. In conjunction with the Convertible Notes, we received warrants
for the right to purchase 3,969 shares of Versa common stock at a weighted average exercise price
of $165 per share. Our ownership percentage would increase to 45 percent if the Convertible Notes
and warrants are converted into common stock.
We have determined that the above warrants represent derivatives subject to fair value accounting.
The fair value is determined based on the Black-Scholes valuation model using historical stock
price, volatility (based on a peer group since Versas common stock is not publicly traded) and
risk-free interest rate assumptions. The fair value of the warrants is included within investment
and loan to affiliate on the consolidated balance sheets and changes in the fair value of the
warrants are included in interest and other income on the consolidated statements of operations.
The fair value of the warrants as of October 31, 2010 and 2009 was $0.2 million and $0.2 million,
respectively. The change in the fair value of the warrants was not material to the consolidated
financial statements for the years ended October 31, 2010, 2009 and 2008. The carrying value of our
investment in and loans to Versa was $9.8 million and $10.1 million as of October 31, 2010 and
2009, respectively.
Note 3. Investments
The following table summarizes the amortized cost basis and fair value of our investments in U.S.
treasury securities at October 31, 2010 and 2009:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Gross |
|
|
Gross |
|
|
|
|
|
|
Amortized |
|
|
unrealized |
|
|
unrealized |
|
|
|
|
|
|
cost |
|
|
gains |
|
|
(losses) |
|
|
Fair value |
|
U.S. government obligations |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
AT October 31, 2010 |
|
$ |
34,090 |
|
|
$ |
74 |
|
|
$ |
|
|
|
$ |
34,164 |
|
AT October 31, 2009 |
|
$ |
7,004 |
|
|
$ |
40 |
|
|
$ |
|
|
|
$ |
7,044 |
|
|
|
|
|
|
|
|
|
|
|
|
2010 |
|
|
2009 |
|
Reported as: |
|
|
|
|
|
|
|
|
Short-term investments |
|
$ |
25,019 |
|
|
$ |
7,004 |
|
Long-term investments |
|
|
9,071 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
$ |
34,090 |
|
|
$ |
7,004 |
|
|
|
|
|
|
|
|
As of October 31, 2010, investment securities had maturity dates ranging from November 18, 2010 to
March 15, 2012, and estimated yields ranging from 0.15 percent to 1.75 percent, with a weighted
average yield of 0.70 percent.
88
Note 4. Inventories
The components of inventory at October 31, 2010 and October 31, 2009 consisted of the following:
|
|
|
|
|
|
|
|
|
|
|
2010 |
|
|
2009 |
|
|
|
|
|
|
|
|
|
|
Raw materials |
|
$ |
15,509 |
|
|
$ |
14,583 |
|
Work-in-process |
|
|
22,786 |
|
|
|
19,790 |
|
|
|
|
|
|
|
|
Gross inventory |
|
|
38,295 |
|
|
|
34,373 |
|
Less amount to reduce certain inventories to
lower of cost or market |
|
|
(4,891 |
) |
|
|
(8,940 |
) |
|
|
|
|
|
|
|
Net inventory |
|
$ |
33,404 |
|
|
$ |
25,433 |
|
|
|
|
|
|
|
|
Raw materials consist mainly of various nickel powders and steels, various other components used in
producing cell stacks and purchased components for BOP. Work-in-process inventory is comprised of
material, labor, and overhead costs incurred to build fuel cell stacks, which are subcomponents of
a power plant. Work in process also includes costs related to power plants in inventory which have
not yet been dedicated to a particular commercial customer contract. The above inventory amounts
include a lower of cost or market adjustment to write down the carrying value of inventory to its
estimated market value.
Note 5. Accounts Receivable
Accounts receivable at October 31, 2010 and 2009 consisted of the following:
|
|
|
|
|
|
|
|
|
|
|
2010 |
|
|
2009 |
|
U.S. Government: |
|
|
|
|
|
|
|
|
Amount billed |
|
$ |
223 |
|
|
$ |
574 |
|
Unbilled recoverable costs |
|
|
605 |
|
|
|
776 |
|
|
|
|
|
|
|
|
|
|
|
828 |
|
|
|
1,350 |
|
|
|
|
|
|
|
|
|
|
Commercial customers: |
|
|
|
|
|
|
|
|
Amount billed |
|
$ |
9,718 |
|
|
$ |
5,439 |
|
Unbilled recoverable costs |
|
|
7,520 |
|
|
|
16,131 |
|
|
|
|
|
|
|
|
|
|
|
17,238 |
|
|
|
21,570 |
|
|
|
|
|
|
|
|
|
|
$ |
18,066 |
|
|
$ |
22,920 |
|
|
|
|
|
|
|
|
We bill customers for power plant sales based on reaching certain milestones. We bill the U.S.
government for research and development contracts based on actual costs incurred, typically in the
month subsequent to incurring costs. Unbilled recoverable costs relate to revenue recognized on
customer contracts that have not been billed. The amounts above are presented net of an allowance
for doubtful accounts of $0.4 million and $19 thousand at October 31, 2010 and 2009, respectively.
89
Note 6. Property, Plant and Equipment
Property, plant and equipment at October 31, 2010 and 2009 consisted of the following:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Estimated |
|
|
|
2010 |
|
|
2009 |
|
|
Useful Life |
|
Land |
|
$ |
524 |
|
|
$ |
524 |
|
|
|
|
|
Building and improvements |
|
|
7,634 |
|
|
|
6,851 |
|
|
10-26 years |
Machinery, equipment and software |
|
|
67,825 |
|
|
|
59,860 |
|
|
3-8 years |
Furniture and fixtures |
|
|
2,749 |
|
|
|
2,604 |
|
|
10 years |
Power plants for use under PPAs |
|
|
13,538 |
|
|
|
17,743 |
|
|
3-10 years |
Construction in progress (1) |
|
|
912 |
|
|
|
6,710 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
93,182 |
|
|
|
94,292 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Less: Accumulated depreciation |
|
|
(66,503 |
) |
|
|
(61,898 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Property, plant and equipment, net |
|
$ |
26,679 |
|
|
$ |
32,394 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(1) |
|
Included in construction in progress are costs of $0.9 million and $0.8 million at
October 31, 2010 and 2009, respectively, to build power plants that will service power
purchase agreement contracts. |
Depreciation expense was $7.4 million, $8.6 million and $8.8 million for the years ended October
31, 2010, 2009 and 2008, respectively.
Note 7. Other Current Assets
Other current assets at October 31, 2010 and October 31, 2009 consisted of the following:
|
|
|
|
|
|
|
|
|
|
|
2010 |
|
|
2009 |
|
|
|
|
|
|
|
|
|
|
Advance payments to vendors (1) |
|
$ |
4,033 |
|
|
$ |
3,362 |
|
Interest receivable (2) |
|
|
55 |
|
|
|
185 |
|
Receivable for state research and development tax credit (3) |
|
|
|
|
|
|
279 |
|
Insurance receivable for power plant damaged during shipping (4) |
|
|
|
|
|
|
1,642 |
|
Prepaid expenses and other (5) |
|
|
1,165 |
|
|
|
1,031 |
|
|
|
|
|
|
|
|
Total |
|
$ |
5,253 |
|
|
$ |
6,499 |
|
|
|
|
|
|
|
|
|
|
|
(1) |
|
Advance payments to vendors relate to inventory purchases. The amounts have been
reduced by a lower of cost or market adjustment of $0.1 million and $0.6 million at October
31, 2010 and 2009, respectively. |
|
(2) |
|
Interest receivable relates to amounts due on investments in U.S. Treasury securities. |
|
(3) |
|
The Company is eligible for a refundable state of Connecticut research and development
tax credit. Approximately $0.2 million related to the fiscal 2009 tax refund was received
prior to October 31, 2010. The fiscal 2008 tax refund of $0.3 million was received
subsequent to October 31, 2009. This tax refund is recorded as part of interest and other
income, net on the consolidated statements of operations. |
|
(4) |
|
In fiscal 2009, one of the Companys power plants was damaged during shipment. The
insurance receivable related to this damage was recovered in full prior to October 31,
2010. |
|
(5) |
|
Primarily relates to other accounts receivable related to POSCO royalties and other
prepaid vendor expenses including insurance, rent and lease payments. |
90
Note 8. Accrued Liabilities
Accrued liabilities at October 31, 2010 and 2009 consisted of the following:
|
|
|
|
|
|
|
|
|
|
|
2010 |
|
|
2009 |
|
|
|
|
|
|
|
|
|
|
Accrued payroll and employee benefits (1) |
|
$ |
3,430 |
|
|
$ |
3,258 |
|
Accrued contract and operating costs (2) |
|
|
3,276 |
|
|
|
3,190 |
|
Reserve for product warranty costs (3) |
|
|
696 |
|
|
|
500 |
|
Reserve for long-term service agreement costs (4) |
|
|
6,592 |
|
|
|
5,950 |
|
Accrued taxes, legal, professional and other (5) |
|
|
2,727 |
|
|
|
910 |
|
|
|
|
|
|
|
|
|
|
$ |
16,721 |
|
|
$ |
13,808 |
|
|
|
|
|
|
|
|
|
|
|
(1) |
|
Balance relate to amounts owe to employees for compensation and benefits as of the end
of the period. |
|
(2) |
|
Balance includes estimated losses accrued on product sales contracts and amounts
estimated as potentially owed to customers related to contract performance. |
|
(3) |
|
Activity in the reserve for product warranty costs during the year ended October 31,
2010 included additions for specific known warranty issues totaling $1.5 million, other
additions for estimates of potential future warranty obligations of
$2.5 million on
contracts in the warranty period and reserve reductions related to actual warranty spend
and reversals to income of $3.8 million as contracts progress through the warranty period
or are beyond the warranty period. |
|
(4) |
|
For our legacy LTSA contracts on power plants with our older 3-year stack design, the
Company has accrued a reserve based on estimated of the future stack replacement and
service costs in excess of the contract value. We expect the replacement of older stacks
produced prior to the five-year stack design will continue in mid 2012.
Reserve estimates for future costs associated with maintaining legacy service agreements
are be determined by a number of factors including the estimated life of the stack, used
replacement stacks available, our limit of liability on service agreements and future
operating plans for the power plant. |
|
(5) |
|
Balance includes accrued sales, use and payroll taxes as well as estimated legal,
professional and other expense estimates as of the end of the period. |
Note 9. Debt and Leases
At October 31, 2010 and 2009, debt consisted of the following:
|
|
|
|
|
|
|
|
|
|
|
2010 |
|
|
2009 |
|
Connecticut Development Authority Note |
|
$ |
3,831 |
|
|
$ |
4,000 |
|
Connecticut Clean Energy Fund Note |
|
|
710 |
|
|
|
650 |
|
Capitalized lease obligations |
|
|
134 |
|
|
|
321 |
|
|
|
|
|
|
|
|
Total debt |
|
$ |
4,675 |
|
|
$ |
4,971 |
|
|
|
|
|
|
|
|
|
|
Less: Current portion of long-term debt |
|
|
(976 |
) |
|
|
(997 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Long-term debt |
|
$ |
3,699 |
|
|
$ |
3,974 |
|
|
|
|
|
|
|
|
In April 2008, we entered into a 10-year loan agreement with the Connecticut Development Authority
to finance equipment purchases associated with manufacturing capacity expansion allowing for a
maximum borrowing of $4.0 million. The stated interest rate is 5 percent and the loan is
collateralized by the assets procured under this loan as well as $4.0 million of additional
machinery and equipment. Interest only payments are required through November 2009. Principal and
interest payments are due commencing in December 2009 through May 2018. The outstanding balance on
the loan was $3.8 million and $4.0 for the years ended October 31, 2010 and 2009, respectively. For
the year ended October 31, 2010 $0.2 million was classified as current portion of long-term debt
and $3.6 million was classified as long-term debt. Interest paid during Fiscal 2010 amounted to
approximately $0.2 million.
91
In April 2006, BFCP entered into a loan agreement with the Connecticut Clean Energy Fund for $0.5
million, secured by assets of BFCP. Loan proceeds were designated for pre-development expenses
associated with the development, construction and operation of a fuel cell generation facility in
Bridgeport, Connecticut (the Project). Interest accrues monthly at an annual rate of 8.75
percent. Repayment of principal and any accrued and unpaid interest is required on the earliest
occurrence of any of the following events: (a) twelve months after the commencement date of the
commercial operation of the Project, (b) the date of consummation and closing of permanent
institutional financing of the Project, (c) the date of consummation and closing of any sale of the
Project and (d) the date upon which certain change in control events occur related to BFCP. None of
these events has occurred and we have not made any payments or prepayments as of October 31, 2010.
The outstanding balance on this loan was $0.7 million, including $0.2 million of accrued interest,
as of October 31, 2010. This note is classified as currently payable as the timing of events that
would result in repayment are not determinable.
We lease computer equipment under a master lease agreements. Lease payment terms are generally
thirty-six months from the date of acceptance for leased equipment.
Aggregate annual principal payments under our loan agreements and capital lease obligations for the
years subsequent to October 31, 2010 are as follows:
|
|
|
|
|
2011 |
|
|
976 |
|
2012 |
|
|
217 |
|
2013 |
|
|
196 |
|
2014 |
|
|
205 |
|
2015 |
|
|
216 |
|
Thereafter |
|
|
2,865 |
|
|
|
|
|
|
|
$ |
4,675 |
|
|
|
|
|
Note 10. Shareholders Equity
Common Stock
During the third quarter of fiscal 2010, we sold 27.6 million shares of our common stock at $1.25
per share in a public offering that generated net cash proceeds of approximately $32.1 million. The
Company intends to use the net proceeds from this offering for product development, project
financing, to expand manufacturing capacity and for general corporate purposes. We also issued 1.0
million shares under employee benefit plans.
During 2009, we issued a total of 15.6 million shares of our common stock. We sold 6.7 million
shares in a registered direct offering for aggregate net proceeds of $22.5 million and in
connection with the execution of the 2009 License Agreement, POSCO purchased 7.0 million shares for
aggregate net proceeds of $25.0 million. We also sold 0.7 million shares on the open market to
fund dividend payments on our outstanding preferred shares and issued 1.2 million shares under
employee benefit plans.
92
Note 11. Redeemable Preferred Stock
Redeemable Series B Preferred Stock
We have 250,000 shares of our 5 percent Series B Cumulative Convertible Perpetual Preferred Stock
(Liquidation Preference $1,000) (Series B Preferred Stock) authorized for issuance. At October
31, 2010 and 2009, there were 64,020 and 64,120 shares, respectively of Series B Preferred Stock
issued and outstanding, with a carrying value of $59.9 million and $60.0 million, respectively.
The shares of our Series B Preferred Stock and the shares of our common stock issuable upon
conversion of the shares of our Series B Preferred Stock are covered by a registration rights
agreement. The following is a summary of certain provisions of our Series B Preferred Stock.
|
|
|
Ranking Shares of Series B Preferred Stock rank with respect to dividend rights and
rights upon our liquidation, winding up or dissolution: |
|
|
|
senior to shares of our common stock; |
|
|
|
junior to our debt obligations; and |
|
|
|
effectively junior to our subsidiaries (i) existing and future liabilities
and (ii) capital stock held by others. |
|
|
|
Dividends The Series B Preferred Stock pays cumulative annual dividends of $50 per
share which are payable quarterly in arrears on February 15, May 15, August 15 and
November 15, which commenced on February 15, 2005, when, as and if declared by the board
of directors. Dividends accumulate and are cumulative from the date of original
issuance. Accumulated dividends on the Series B Preferred Stock do not bear interest. |
|
|
|
|
The dividend rate is subject to upward adjustment as set forth in the Certificate of
Designation if we fail to pay, or to set apart funds to pay, any quarterly dividend. The
dividend rate is also subject to upward adjustment as set forth in the Registration Rights
Agreement entered into with the Initial Purchasers if we fail to satisfy our registration
obligations with respect to the Series B Preferred Stock (or the underlying common shares)
under the Registration Rights Agreement. |
|
|
|
|
No dividends or other distributions may be paid or set apart for payment on our common
shares (other than a dividend payable solely in shares of a like or junior ranking) unless
all accumulated and unpaid Series B Preferred Stock dividends have been paid or funds or
shares of common stock have been set aside for payment of accumulated and unpaid Series B
Preferred Stock dividends. |
|
|
|
|
The dividend on the Series B Preferred Stock may be paid in cash; or at the option of the
holder, in shares of our common stock, which will be registered pursuant to a registration
statement to allow for the immediate sale of these common shares in the public market.
Dividends of $3.2 million were paid in cash in each of the years ended October 31, 2010
and 2009. There were no cumulative unpaid dividends at October 31, 2010 and 2009. |
|
|
|
Liquidation The Series B Preferred Stock stockholders are entitled to receive, in
the event that we are liquidated, dissolved or wound up, whether voluntary or
involuntary, $1,000 per share plus all accumulated and unpaid dividends to the date of
that liquidation, dissolution, or winding up (Liquidation Preference). Until the
holders of Series B Preferred Stock receive their Liquidation Preference in full, no
payment will be made on any junior shares, including shares of our common stock. After
the Liquidation Preference is paid in full, holders of the Series B Preferred Stock will
not be entitled to receive any further distribution of our assets. At October 31, 2010
and 2009, the Series B Preferred Stock had a Liquidation Preference of $64.0 million and
$64.1 million, respectively. |
|
|
|
Conversion Rights Each Series B Preferred Stock share may be converted at any time,
at the option of the holder, into 85.1064 shares of our common stock (which is
equivalent to an initial conversion price of $11.75 per share) plus cash in lieu of
fractional shares. The conversion rate is subject to adjustment upon the occurrence of
certain events, as described below, but will not be adjusted for accumulated and unpaid
dividends. If converted, holders of Series B Preferred Stock do not receive a cash
payment for all accumulated and unpaid dividends; rather, all accumulated and unpaid
dividends are cancelled. |
93
|
|
|
Beginning after November 20, 2009 we may, at our option, cause shares of Series B
Preferred Stock to be automatically converted into that number of shares of our common
stock that are issuable at the then prevailing conversion rate. We may exercise our
conversion right only if the closing price of our common stock exceeds 150 percent of the
then prevailing conversion price
($11.75 at November 20, 2009) for 20 trading days during any consecutive 30 trading day
period, as described in the Certificate of Designation. |
|
|
|
If holders of Series B Preferred Stock elect to convert their shares in connection with
certain fundamental changes (as described below and in the Certificate of Designation), we
will in certain circumstances increase the conversion rate by a number of additional
shares of common stock upon conversion or, in lieu thereof, we may in certain
circumstances elect to adjust the conversion rate and related conversion obligation so
that shares of our Series B Preferred Stock are converted into shares of the acquiring or
surviving company, in each case as described in the Certificate of Designation. |
|
|
|
|
The adjustment of the conversion price is to prevent dilution of the interests of the
holders of the Series B Preferred Stock from the following: |
|
|
|
Issuances of common stock as a dividend or distribution to holders of our
common stock; |
|
|
|
Common stock share splits or share combinations; |
|
|
|
Issuances to holders of our common stock of any rights, warrants or options
to purchase our common stock for a period of less than 60 days; and |
|
|
|
Distributions of assets, evidences of indebtedness or other property to
holders of our common stock. |
|
|
|
During 2010, holders of Series B preferred shares converted 100 preferred shares and
received 8,510 shares of the Companys common stock in exchange. |
|
|
|
Redemption We do not have the option to redeem the shares of Series B Preferred
Stock. However, holders of the Series B Preferred Stock can require us to redeem all or
part of their shares at a redemption price equal to the Liquidation Preference of the
shares to be redeemed in the case of a fundamental change. A fundamental change will
be deemed to have occurred if any of the following occurs: |
|
|
|
any person or group is or becomes the beneficial owner, directly or
indirectly, of 50 percent or more of the total voting power of all classes of
our capital stock then outstanding and normally entitled to vote in the election
of directors; |
|
|
|
during any period of two consecutive years, individuals who at the beginning
of such period constituted the Board of Directors (together with any new
directors whose election by our Board of Directors or whose nomination for
election by our shareholders was approved by a vote of two-thirds of our
directors then still in office who were either directors at the beginning of
such period or whose election of nomination for election was previously so
approved) cease for any reason to constitute a majority of our directors then in
office; |
|
|
|
the termination of trading of our common stock on the Nasdaq Stock Market and
such shares are not approved for trading or quoted on any other U.S. securities
exchange; or |
|
|
|
we consolidate with or merge with or into another person or another person
merges with or into us or the sale, assignment, transfer, lease, conveyance or
other disposition of all or substantially all of our assets and certain of our
subsidiaries, taken as a whole, to another person and, in the case of any such
merger or consolidation, our securities that are outstanding immediately prior
to such transaction and which represent 100 percent of the aggregate voting
power of our voting stock are changed into or exchanged for cash, securities or
property, unless pursuant to the transaction such securities are changed into
securities of the surviving person that represent, immediately after such
transaction, at least a majority of the aggregate voting power of the voting
stock of the surviving person. |
94
|
|
|
Notwithstanding the foregoing, holders of shares of Series B Preferred Stock will not have
the right to require us to redeem their shares if: |
|
|
|
the last reported sale price of shares of our common stock for any five
trading days within the 10 consecutive trading days ending immediately before
the later of the fundamental change or its announcement equaled or exceeded 105
percent of the conversion price of the shares of Series B Preferred Stock
immediately before the fundamental change or announcement; |
|
|
|
at least 90 percent of the consideration (excluding cash payments for
fractional shares) and, in respect of dissenters appraisal rights, if the
transaction constituting the fundamental change consists of shares of capital
stock traded on a U.S. national securities exchange, or which will be so traded
or quoted when issued or exchanged in connection with a fundamental change, and
as a result of the transaction, shares of Series B Preferred Stock become
convertible into such publicly traded securities; or |
|
|
|
in the case of fundamental change event in the fourth bullet above, the
transaction is affected solely to change our jurisdiction of incorporation. |
|
|
|
We may, at our option, elect to pay the redemption price in cash or, in shares of our
common stock valued at a discount of 5 percent from the market price of shares of our
common stock, or any combination thereof. Notwithstanding the foregoing, we may only pay
such redemption price in shares of our common stock that are registered under the
Securities Act of 1933 and eligible for immediate sale in the public market by
non-affiliates of the Company. |
|
|
|
Voting Rights Holders of Series B Preferred Stock currently have no voting rights;
however, holders may receive certain voting rights, as described in the Certificate of
Designation, if (1) dividends on any shares of Series B Preferred Stock, or any other
class or series of stock ranking on a parity with the Series B Preferred Stock with
respect to the payment of dividends, shall be in arrears for dividend periods, whether
or not consecutive, for six calendar quarters or (2) we fail to pay the redemption
price, plus accrued and unpaid dividends, if any, on the redemption date for shares of
Series B Preferred Stock following a fundamental change. |
|
|
|
So long as any shares of Series B Preferred Stock remain outstanding, we will not, without
the consent of the holders of at least two-thirds of the shares of Series B Preferred
Stock outstanding at the time (voting separately as a class with all other series of
preferred stock, if any, on parity with our Series B Preferred Stock upon which like
voting rights have been conferred and are exercisable) issue or increase the authorized
amount of any class or series of shares ranking senior to the outstanding shares of the
Series B Preferred Stock as to dividends or upon liquidation. In addition, we will not,
subject to certain conditions, amend, alter or repeal provisions of our certificate of
incorporation, including the certificate of designation relating to the Series B Preferred
Stock, whether by merger, consolidation or otherwise, so as to adversely amend, alter or
affect any power, preference or special right of the outstanding shares of Series B
Preferred Stock or the holders thereof without the affirmative vote of not less than
two-thirds of the issued and outstanding Series B Preferred Stock shares. |
95
Series 1 Preferred Shares Redeemable minority interest
In connection with our acquisition of Global Thermoelectric Inc. (Global) in November 2003, we
acquired 1,000,000 Series 2 Preferred Shares (Series 2 Preferred Shares). With the sale of
Global in May of 2004, the Series 2 Preferred Shares were cancelled, and replaced with
substantially equivalent Series 1 Preferred Shares (Series 1 Preferred Shares) issued by FCE Ltd.
The fair value of the Series 2 Preferred Shares was determined at the acquisition date of Global
using the income method. In applying this method, cash flows were estimated for the life of the
securities and then discounted to present value to arrive at an indication of fair value. Amounts
projected and then discounted included future dividend payments and conversion of the securities in
2020. Implicit in this valuation are certain assumptions regarding timing and payment of dividends
and the ultimate conversion of the securities. Because the Series 1 Preferred Shares were issued
as a replacement of the Series 2 Preferred Shares with equivalent terms and dividend requirements,
the carrying value of the Series 1 Preferred Shares was set equal to the carrying value (original
fair value plus any accretion of the fair value discount) of the Series 2 Preferred Shares at the
date the Series 2 Preferred Shares were cancelled. The carrying value of the Series 1 Preferred
Shares is adjusted quarterly to reflect dividend payments and accretion of the fair value discount
established at the acquisition date. As of October 31, 2010 and 2009, the Series 1 Preferred
Shares had a carrying value of $16.8 million and $15.0 million, respectively.
The significant terms of the Series 1 Preferred Shares include the following:
|
|
|
Voting Rights The holders of the Series 1 Preferred shares are not entitled to any
voting rights or to receive notice of or to attend any meeting of the shareholders of
FCE Ltd., but shall be entitled to receive notice of meetings of shareholders of FCE
Ltd. called for the purpose of authorizing the dissolution or sale of its assets or a
substantial part thereof. |
|
|
|
Dividends Quarterly dividends of Cdn.$312,500 ($306,719 based on the October 31,
2010 exchange rate of Cdn.$0.98 to U.S.$1.00) accrue on the Series 1 Preferred Shares
(subject to possible reduction pursuant to the terms of the Series 1 Preferred Shares on
account of increases in the price of our common stock). We have agreed to pay a minimum
of Cdn.$500,000 in cash or common stock annually to Enbridge, the sole holder of the
Series 1 Preferred Shares, as long as Enbridge holds these shares. Interest accrues on
cumulative unpaid dividends at an annual rate of 9 percent, compounded quarterly. All
cumulative unpaid dividends must be paid by December 31, 2010. Using an exchange rate of
Cdn.$0.98 to U.S.$1.00, cumulative unpaid dividends and accrued interest was $11.9
million as of October 31, 2010. Subsequent to December 31, 2010 the required annual
dividend payment increases to Cdn.$1.25 million ($1.23 million based on an exchange rate
of Cdn.$0.98 to U.S.$1.00). We have guaranteed FCE Ltd.s dividend obligations under the
Series 1 Preferred Shares. During the year ended October 31, 2010, we paid cash
dividends totaling Cdn.$500,000. Refer to Note 19 Subsequent Events which describes
changes to this obligation since the Balance Sheet date. |
|
|
|
Dividend and accrued interest payments can be made in cash or common stock, at the option
of FCE Ltd., and such shares issued may be unregistered. If FCE Ltd. elects to make such
payments using shares of common stock, the number of common shares is determined by
dividing the cash dividend obligation by 95 percent of the volume weighted average price
at which the common shares have been traded on NASDAQ during the 20 consecutive trading
days preceding the end of the calendar quarter for which such dividend in common shares is
to be paid converted into Canadian dollars using the Bank of Canadas noon rate of
exchange on the day of determination. |
96
|
|
|
Redemption FCE Ltd. may redeem in whole or in part the Series 1 Preferred Shares if
the trading price of our common stock for a calculated period is not less than 120
percent of the current
conversion price plus all accrued and unpaid dividends. The Series 1 Preferred Shares are
redeemable by FCE Ltd. for Cdn.$25 per share plus all unpaid dividends and accrued
interest. Holders of the Series 1 Preferred Shares do not have any mandatory or
conditional redemption rights. |
|
|
|
Liquidation or Dissolution In the event of the liquidation or dissolution of FCE
Ltd., the holders of Series 1 Preferred Shares will be entitled to receive Cdn.$25 per
share plus all unpaid dividends and accrued interest. We have guaranteed any
liquidation obligations of FCE Ltd. |
|
|
|
Conversion Rights A holder of Series 1 Preferred Shares has the right to convert
such shares into fully paid and non-assessable shares of FuelCell common stock at the
following conversion prices: |
|
|
|
Cdn$129.46 per share of our common stock after July 31, 2010 until July 31,
2015; |
|
|
|
Cdn$138.71 per share of our common stock after July 31, 2015 until July 31,
2020; and |
|
|
|
at any time after July 31, 2020, at a price equal to 95 percent of the then
current market price (in Cdn.$) of shares of our common stock at the time of
conversion. |
|
|
|
The conversion rates set forth above shall be adjusted if we: (i) split our shares of
common stock; (ii) pay a stock dividend; (iii) issue rights, options or other convertible
securities to our common stockholders enabling them to acquire our common stock at a price
less than 95 percent of the then-current price; or (iv) fix a record date to distribute to
our common stockholders shares of any class of securities, indebtedness or assets. |
Derivative liability related to Series 1 Preferred Shares
The conversion feature and variable dividend contained in the terms of the Series 1 Preferred
Shares are not clearly and closely related to the characteristics of the Series 1 Preferred Shares.
Accordingly, these features qualify as embedded derivative instruments and are required to be
accounted for separately and recorded as derivative financial instruments at fair value.
The conversion feature is valued using a lattice model. This is a one-factor model used to project
stochastic stock prices, while risk free rates, discount rates and foreign exchange rates are
deterministic factors. Based on the pay-off profiles of the Series 1 Preferred Shares, it is
assumed that we will exercise the call option to force conversion in 2020. Conversion after 2020
delivers a fixed pay-off to the investor, and is modeled as a fixed payment in 2020. The
cumulative dividend is modeled as a quarterly cash dividend component (to satisfy minimum dividend
payment requirement), and a one-time cumulative dividend payment in 2010. The cumulative dividend
is compounded at a 2.45 percent quarterly rate. Call option strikes are adjusted for the
cumulative dividend and the conversion ratio is adjusted by the accreted notional until 2010.
The variable dividend is valued using a Monte Carlo simulation model. The embedded derivative is
defined as the difference between the value of a normal 5 percent annual dividend payment stream,
and the value of a stock price and foreign exchange rate linked dividend payment stream. Future
stock prices and exchange rates are simulated following geometric Brownian motion to determine the
stock/FX linked dividend going out to the year 2020, when the Series 1 Preferred Shares are assumed
to be force converted.
The assumptions used in these valuation models include historical stock price volatility, risk-free
interest rate and a credit spread based on the yield indexes of technology high yield bonds,
foreign exchange volatility as the security is denominated in Canadian dollars, and the closing
price of our common stock. The aggregate fair value of these derivatives included within long-term
debt and other liabilities on the consolidated balance sheets as of October 31, 2010 and 2009 was
$0.5 million.
97
Note 12. Segment Information
We are engaged in the development, design, production and sale of high temperature fuel cells for
clean electric power generation. Critical to the success of our business is, among other things,
our research and development efforts, both through customer-sponsored projects and
company-sponsored projects. Management considers our research and development activities and the
production and sale of our fuel cell products as one activity. Accordingly, we have identified one
business segment: fuel cell power plant production and research.
Revenues, by geographic location (based on the customers ordering location) for the years ended
October 31, 2010, 2009 and 2008 was as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2010 |
|
|
2009 |
|
|
2008 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
South Korea |
|
$ |
40,148 |
|
|
$ |
56,100 |
|
|
$ |
46,160 |
|
United States |
|
|
28,764 |
|
|
|
30,450 |
|
|
|
50,705 |
|
Canada |
|
|
136 |
|
|
|
74 |
|
|
|
159 |
|
Germany |
|
|
681 |
|
|
|
991 |
|
|
|
2,856 |
|
Japan |
|
|
48 |
|
|
|
401 |
|
|
|
855 |
|
|
|
|
|
|
|
|
|
|
|
Total |
|
$ |
69,777 |
|
|
$ |
88,016 |
|
|
$ |
100,735 |
|
|
|
|
|
|
|
|
|
|
|
Note 13. Benefit Plans
We have shareholder approved equity incentive plans, a shareholder approved Section 423 Stock
Purchase Plan (the ESPP) and an employee tax-deferred savings plan, which are described in more
detail below.
Equity Incentive Plans
The Board adopted the 2006 and 2010 Equity Incentive Plans (collectively, the Equity Plans).
Pursuant to the Equity Plans, 5.0 million shares of common stock were reserved for issuance. The
Board is authorized to grant incentive stock options, nonstatutory stock options, stock
appreciation rights (SARs), restricted stock awards (RSAs), restricted stock units, performance
units, performance shares, dividend equivalent rights and other stock based awards to our officers,
key employees and non-employee directors. Stock options, RSAs and SARs have restrictions as to
transferability. Stock option exercise prices are fixed by the Board but shall not be less than the
fair market value of our common stock on the date of the grant. SARs may be granted in conjunction
with stock options. Stock options generally vest ratably over four years and expire 10 years from
the date of grant. As of October 31, 2010, there were 2,005,181 shares available for grant. As of
October 31, 2010, equity awards outstanding consisted of incentive stock options, nonstatutory
stock options and RSAs. The Company has not issued any other type of equity award to its officers,
key employees and non-employee directors. The 1998 Equity Incentive Plan remains in effect only to
the extent of awards outstanding under the plan as of October 31, 2010.
98
We account for stock options awarded to employees and non-employee directors under the fair value
method. The fair value of stock options is estimated on the grant date using the Black-Scholes
option valuation model and the following weighted-average assumptions:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2010 |
|
|
2009 |
|
|
2008 |
|
Expected life (in years) |
|
|
7.0 |
|
|
|
6.8 |
|
|
|
6.7 |
|
Risk free interest rate |
|
|
3.4 |
% |
|
|
2.3 |
% |
|
|
3.2 |
% |
Volatility |
|
|
72.2 |
% |
|
|
72.4 |
% |
|
|
64.0 |
% |
Dividends yield |
|
|
0.0 |
% |
|
|
0.0 |
% |
|
|
0.0 |
% |
The expected life is the period over which our employees are expected to hold the options and is
based on historical data for similar grants. The risk free interest rate is based on the expected
U.S. Treasury rate over the expected life. Expected volatility is based on the historical
volatility of our stock. Dividend yield is based on our expected dividend payments over the
expected life.
Share-based compensation was reflected in the consolidated statements of operations as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2010 |
|
|
2009 |
|
|
2008 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cost of product sales and revenues |
|
$ |
761 |
|
|
$ |
1,029 |
|
|
$ |
1,004 |
|
Cost of research and development contracts |
|
|
175 |
|
|
|
188 |
|
|
|
235 |
|
General and administrative expense |
|
|
1,397 |
|
|
|
2,802 |
|
|
|
3,287 |
|
Research and development expense |
|
|
627 |
|
|
|
780 |
|
|
|
940 |
|
|
|
|
|
|
|
|
|
|
|
Total share-based compensation |
|
$ |
2,960 |
|
|
$ |
4,799 |
|
|
$ |
5,466 |
|
|
|
|
|
|
|
|
|
|
|
The following table summarizes our stock option activity for the year ended October 31, 2010:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Weighted- |
|
|
|
|
|
|
|
Average |
|
Options |
|
Shares |
|
|
Option Price |
|
Outstanding at October 31, 2009 |
|
|
5,740,705 |
|
|
$ |
10.86 |
|
Granted |
|
|
171,139 |
|
|
$ |
2.89 |
|
Exercised |
|
|
|
|
|
$ |
0.00 |
|
Cancelled |
|
|
(793,643 |
) |
|
$ |
14.57 |
|
|
|
|
|
|
|
|
|
Outstanding at October 31, 2010 |
|
|
5,118,201 |
|
|
$ |
10.15 |
|
|
|
|
|
|
|
|
|
The weighted average grant-date fair value per share for options granted during the periods ended
October 31, 2010, 2009 and 2008 was $2.02, $1.97 and $5.44, respectively. There were no options
exercised in fiscal 2010. The total intrinsic value of options exercised during the periods ended
October 31, 2009 and 2008 was $0.1 million and $2.2 million, respectively.
99
The following table summarizes information about stock options outstanding and exercisable at
October 31, 2010:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Options Outstanding |
|
|
Options Exercisable |
|
|
|
|
|
|
|
Weighted |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Average |
|
|
Weighted Average |
|
|
|
|
|
|
Weighted Average |
|
Range of |
|
Number |
|
|
Remaining |
|
|
Exercise |
|
|
Number |
|
|
Exercise |
|
Exercise Prices |
|
outstanding |
|
|
Contractual Life |
|
|
Price |
|
|
exercisable |
|
|
Price |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
$0.27 $5.10 |
|
|
383,091 |
|
|
|
8.8 |
|
|
$ |
2.89 |
|
|
|
336,105 |
|
|
$ |
2.87 |
|
$5.11 $9.92 |
|
|
2,909,087 |
|
|
|
5.6 |
|
|
$ |
8.01 |
|
|
|
2,320,137 |
|
|
$ |
7.96 |
|
$9.93 $14.74 |
|
|
1,320,523 |
|
|
|
3.7 |
|
|
$ |
12.10 |
|
|
|
1,309,223 |
|
|
$ |
12.11 |
|
$14.75 $19.56 |
|
|
139,500 |
|
|
|
1.3 |
|
|
$ |
15.81 |
|
|
|
139,500 |
|
|
$ |
15.81 |
|
$19.57 $24.39 |
|
|
217,000 |
|
|
|
0.4 |
|
|
$ |
23.01 |
|
|
|
217,000 |
|
|
$ |
23.01 |
|
$24.40 $29.21 |
|
|
15,000 |
|
|
|
0.4 |
|
|
$ |
25.25 |
|
|
|
15,000 |
|
|
$ |
25.25 |
|
$29.22 $34.03 |
|
|
134,000 |
|
|
|
0.1 |
|
|
$ |
29.91 |
|
|
|
134,000 |
|
|
$ |
29.91 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
5,118,201 |
|
|
|
4.9 |
|
|
$ |
10.15 |
|
|
|
4,470,965 |
|
|
$ |
10.48 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
There was no intrinsic value for options outstanding and exercisable at October 31, 2010.
During fiscal year 2010, we granted 774,849 RSAs to employees. RSA expense is based on the fair
value of the award at the date of grant and is amortized over the vesting period, generally four
years. The weighted average grant-date fair value of RSAs was $2.65 per share. During the year,
25,160 RSAs were cancelled. At October 31, 2010, there were 1,207,534 outstanding RSAs with an
average remaining life of 1.8 years and an aggregate intrinsic value of $1.4 million.
As of October 31, 2010, total compensation cost related to nonvested stock options and RSAs not yet
recognized was $1.8 million and $2.8 million, respectively, which is expected to be recognized over
the next 1.1 and 2.8 years, respectively, on a weighted-average basis.
Stock may be issued to employees as part of the annual incentive bonus. During fiscal 2010, 2009
and 2008, we issued 233,822, 355,253 and 140,271 shares of common stock, respectively, in lieu of
cash bonuses with values of $0.7 million, $1.1 million and $1.1 million, respectively, to fulfill
the accrued obligation from each of the prior fiscal years.
During fiscal 2008 we issued 9,387 shares of common stock to directors as compensation in lieu of
cash. No shares were issued to directors as compensation in 2010 or 2009.
Employee Stock Purchase Plan
There were 900,000 shares of common stock reserved for issuance under the ESPP. Under the ESPP,
eligible employees have the right to purchase shares of common stock at the lesser of (i) 85
percent of the last reported sale price of our common stock on the first business day of the
offering period, or (ii) 85 percent of the last reported sale price of the common stock on the last
business day of the offering period, in either case rounded up to avoid impermissible trading
fractions. Shares issued pursuant to the ESPP contain a legend restricting the transfer or sale of
such common stock for a period of six months after the date of purchase. As of October 31, 2010,
there were 127,703 shares of common stock available for issuance under the ESPP.
100
ESPP activity for the year ended October 31, 2010 was as follows:
|
|
|
|
|
|
|
Number of |
|
Options |
|
Shares |
|
Balance at October 31, 2009 |
|
|
207,207 |
|
Issued @ 2.70 |
|
|
(39,858 |
) |
Issued @ 2.34 |
|
|
(39,646 |
) |
|
|
|
|
Outstanding at October 31, 2010 |
|
|
127,703 |
|
|
|
|
|
The fair value of shares under the ESPP was determined at the grant date using the Black-Scholes
option-pricing model with the following weighted average assumptions:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2010 |
|
|
2009 |
|
|
2008 |
|
Expected life (in years) |
|
|
0.5 |
|
|
|
0.5 |
|
|
|
0.5 |
|
Risk free interest rate |
|
|
0.2 |
% |
|
|
0.7 |
% |
|
|
2.1 |
% |
Volatility |
|
|
94.0 |
% |
|
|
99.0 |
% |
|
|
68.9 |
% |
Dividends yield |
|
|
0.0 |
% |
|
|
0.0 |
% |
|
|
0.0 |
% |
The weighted-average fair value of shares issued under the ESPP during fiscal 2010 was $2.52 per
share.
Employee Tax-Deferred Savings Plans
We offer a 401(k) plan (the Plan) to all full time employees that provides for tax-deferred
salary deductions for eligible employees (beginning the first month following an employees hire
date). Employees may choose to make voluntary contributions of their annual compensation to the
Plan, limited to an annual maximum amount as set periodically by the Internal Revenue Service. We
provide discretionary matching contributions equal to 100 percent of the employees contribution
amount, up to a maximum of 6 percent of the employees annual salary. Participants are required to
contribute a minimum of 3 percent in order to be eligible to participate and receive the matching
contribution. Matching contributions begin vesting after one year and are fully vested after five
years. Employee contributions are fully vested when made. Under the Plan, there is no option
available to the employee to receive or purchase our common stock. In February 2009, we suspended
our matching contribution. Matching contributions under the Plan were $0.5 million and $1.7 million
for the fiscal years ended October 31, 2009 and 2008, respectively.
Note 14. Income Taxes
The components of loss from continuing operations before income taxes for the fiscal years ended
October 31, 2010, 2009, and 2008 were as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2010 |
|
|
2009 |
|
|
2008 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
U.S. |
|
$ |
(53,868 |
) |
|
$ |
(66,582 |
) |
|
$ |
(91,500 |
) |
Foreign |
|
|
(2,367 |
) |
|
|
(2,092 |
) |
|
|
(1,857 |
) |
|
|
|
|
|
|
|
|
|
|
Loss before income taxes |
|
$ |
(56,235 |
) |
|
$ |
(68,674 |
) |
|
$ |
(93,357 |
) |
|
|
|
|
|
|
|
|
|
|
There was a current income tax expense of $0.1 million related to foreign withholding taxes in
South Korea and no deferred federal income tax expense (benefit) for the year ended October 31,
2010. There was no current or deferred federal income tax expense (benefit) for the years ended
October 31, 2009 and 2008. Franchise tax expense, which is included in administrative and selling
expenses, was $0.2 million, $0.2 million and $0.2 million for the years ended October 31, 2010,
2009 and 2008, respectively.
101
The reconciliation of the federal statutory income tax rate to our effective income tax rate for
the years ended October 31, 2010, 2009 and 2008 was as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2010 |
|
|
2009 |
|
|
2008 |
|
Statutory federal income tax rate |
|
|
(34.0 |
)% |
|
|
(34.0 |
)% |
|
|
(34.0 |
)% |
|
|
|
|
|
|
|
|
|
|
|
|
|
Increase (decrease) in income taxes resulting from: |
|
|
|
|
|
|
|
|
|
|
|
|
State taxes net of Federal benefits |
|
|
(2.0 |
) |
|
|
(1.6 |
) |
|
|
(3.4 |
) |
Net
operating loss adjustment |
|
|
1.6 |
|
|
|
0.5 |
|
|
|
(1.3 |
) |
Nondeductible expenditures |
|
|
1.7 |
|
|
|
1.7 |
|
|
|
1.4 |
|
Change in State tax rate |
|
|
7.6 |
|
|
|
12.8 |
|
|
|
|
|
Other, net |
|
|
|
|
|
|
0.1 |
|
|
|
0.7 |
|
Valuation allowance |
|
|
25.1 |
|
|
|
20.5 |
|
|
|
36.6 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Effective income tax rate |
|
|
|
% |
|
|
|
% |
|
|
|
% |
|
|
|
|
|
|
|
|
|
|
Our deferred tax assets and liabilities consisted of the following at October 31, 2010 and 2009:
|
|
|
|
|
|
|
|
|
|
|
2010 |
|
|
2009 |
|
Deferred tax assets: |
|
|
|
|
|
|
|
|
Compensation and benefit accruals |
|
$ |
3,855 |
|
|
$ |
3,665 |
|
Bad debt and other reserves |
|
|
3,028 |
|
|
|
2,444 |
|
Capital loss and tax credit carry-forwards |
|
|
5,885 |
|
|
|
5,456 |
|
Investment in Versa |
|
|
2,491 |
|
|
|
2,305 |
|
Net operating loss |
|
|
188,963 |
|
|
|
175,363 |
|
Deferred license revenue |
|
|
3,178 |
|
|
|
3,646 |
|
Lower of cost or market inventory reserves |
|
|
1,897 |
|
|
|
3,635 |
|
|
|
|
|
|
|
|
Gross deferred tax assets: |
|
|
209,297 |
|
|
|
196,514 |
|
Valuation allowance |
|
|
(207,622 |
) |
|
|
(194,087 |
) |
|
|
|
|
|
|
|
Deferred tax assets after valuation allowance |
|
|
1,675 |
|
|
|
2,427 |
|
Deferred tax liability: |
|
|
|
|
|
|
|
|
Investment in partnerships |
|
|
(581 |
) |
|
|
(509 |
) |
Accumulated depreciation |
|
|
(1,094 |
) |
|
|
(1,918 |
) |
|
|
|
|
|
|
|
Gross deferred tax liability |
|
|
(1,675 |
) |
|
|
(2,427 |
) |
|
|
|
|
|
|
|
Net deferred tax assets |
|
$ |
|
|
|
$ |
|
|
|
|
|
|
|
|
|
We continually evaluate our deferred tax assets as to whether it is more likely than not that
the deferred tax assets will be realized. In assessing the realizability of our deferred tax
assets, management considers the scheduled reversal of deferred tax liabilities, projected future
taxable income and tax planning strategies. Based on the projections for future taxable income
over the periods in which the deferred tax assets are realizable, management believes that
significant uncertainty exists surrounding the recoverability of the deferred tax assets. As a
result, we recorded a full valuation allowance against our net deferred tax assets. Approximately
$4.2 million of the valuation allowance will reduce additional paid in capital upon subsequent
recognition of any related tax benefits.
At October 31, 2010, we had federal and state NOL carryforwards of $541 million and $343 million,
respectively, for which a portion of the NOL has not been recognized in connection with share-based
compensation. The Federal NOLs expire in varying amounts from 2020 through 2030 while state NOLs
expire in varying amounts from 2011 through 2030. Additionally, we had $8.7 million of state tax
credits available, of which $1.0 million expires in 2018. The remaining credits do not expire.
Certain transactions involving the Companys beneficial ownership occurred in fiscal 2010 and prior
years, which could have resulted in a stock ownership change for purposes of Section 382 of the
Internal Revenue Code of 1986, as amended. We have completed a detailed Section 382 study in
fiscal 2010 to determine if any of our NOL and credit carryovers will be subject to limitation.
Based on that study we have determined that there was no ownership change as of the end of our 2010
fiscal year under Section 382.
102
As discussed in Note 1, we adopted guidance for how a company should recognize, measure, present,
and disclose in its financial statements uncertain tax positions that the company has taken or
expects to take on a tax return (including a decision whether to file or not file a return in a
particular jurisdiction). There was no cumulative effect on retained earnings from the adoption of
this guidance, although NOL carryforwards and the related valuation allowance were adjusted by
$15.7 million.
The liability for unrecognized tax benefits at October 31, 2010 and 2009 was $15.7 million. This
amount is directly associated with a tax position taken in a year in which federal and state NOL
carryforwards were generated. Accordingly, the amount of unrecognized tax benefit has been
presented as a reduction in the reported amounts of our federal and state NOL carryforwards. It is
our policy to record interest and penalties on unrecognized tax benefits as income taxes; however,
because of our significant NOLs, no provision for interest or penalties has been recorded.
We file income tax returns in the U.S. and various states, primarily Connecticut and California. We
are open to examination by the Internal Revenue Service and various states in which we file for
fiscal years 1998 to the present. We are currently not under any income tax examinations.
Note 15. Earnings Per Share
Basic earnings (loss) per common share (EPS) are generally calculated as income (loss) available
to common shareholders divided by the weighted average number of common shares outstanding.
Diluted EPS is generally calculated as income (loss) available to common shareholders divided by
the weighted average number of common shares outstanding plus the dilutive effect of common share
equivalents. The calculation of basic and diluted EPS for the years ended October 31, 2010, 2009
and 2008 was as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2010 |
|
|
2009 |
|
|
2008 |
|
Numerator |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss |
|
$ |
(56,326 |
) |
|
$ |
(68,674 |
) |
|
$ |
(93,357 |
) |
Preferred stock dividend |
|
|
(3,201 |
) |
|
|
(3,208 |
) |
|
|
(3,208 |
) |
Net loss attributable to noncontrolling interest |
|
|
663 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss to common shareholders |
|
$ |
(58,864 |
) |
|
$ |
(71,882 |
) |
|
$ |
(96,565 |
) |
|
|
|
|
|
|
|
|
|
|
Denominator |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Weighted average basic common shares |
|
|
93,925,863 |
|
|
|
72,392,928 |
|
|
|
68,570,689 |
|
Effect of dilutive securities (1) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Weighted average diluted common shares |
|
|
93,925,863 |
|
|
|
72,392,928 |
|
|
|
68,570,689 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Basic loss per share |
|
|
(0.63 |
) |
|
|
(0.99 |
) |
|
|
(1.41 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Diluted loss per share (1) |
|
|
(0.63 |
) |
|
|
(0.99 |
) |
|
|
(1.41 |
) |
|
|
|
(1) |
|
Due to the net loss to common shareholders in each of the years presented above, diluted
earnings per share was computed without consideration to potentially dilutive instruments as
their inclusion would have been antidilutive. Potentially dilutive instruments include stock
options, warrants and convertible preferred stock. At October 31, 2010, 2009 and 2008, there
were options to purchase 5.1 million, 5.7 million and 6.0 million shares of common stock,
respectively. There were no outstanding warrants as of October 31, 2010 and 2009,
respectively. As of October 31, 2008, there were outstanding warrants to purchase 500,000
shares of common stock. See Note 11 for further information on preferred stock. |
103
Note 16. Commitments and Contingencies
Lease agreements
In December 2006, we entered into a master lease agreement that allows for the lease of computer
equipment up to an aggregate cost of $2.5 million. As of October 31, 2010, we had capital lease
obligations of $0.1 million. Lease payment terms are thirty six months from the date of lease.
We also lease certain computer and office equipment and manufacturing facilities in Torrington, and
Danbury, Connecticut under operating leases expiring on various dates through 2015. Rent expense
was $1.4 million, $1.4 million and $1.3 million for the fiscal years ended October 2010, 2009 and
2008, respectively.
Non-cancelable minimum payments applicable to operating and capital leases as of October 31, 2010
were as follows:
|
|
|
|
|
|
|
|
|
|
|
Operating |
|
|
Capital |
|
|
|
Leases |
|
|
Leases |
|
2011 |
|
$ |
809 |
|
|
$ |
103 |
|
2012 |
|
|
780 |
|
|
|
31 |
|
2013 |
|
|
772 |
|
|
|
|
|
2014 |
|
|
773 |
|
|
|
|
|
2015 |
|
|
448 |
|
|
|
|
|
Thereafter |
|
|
75 |
|
|
|
|
|
|
|
|
|
|
|
|
Total |
|
$ |
3,657 |
|
|
$ |
134 |
|
|
|
|
|
|
|
|
Service and warranty agreements
Under the provisions of our LTSAs, we provide services to maintain, monitor, and repair customer
power plants to meet minimum operating levels. Should the power plant not meet the minimum
operating levels, we may be required to replace the fuel cell stack with a new or used stack. Our reserves on LTSA contracts
totaled $6.6 million, $6.0 million and $4.0 million as of October 31, 2010, 2009 and 2008, respectively. Our reserve estimates include cost assumptions based on what we anticipate the service
requirements will be to meet our contractual obligations on a
contract by contract basis. We have incurred and expect to continue to incur costs in excess of our minimum contractual liabilities in
order to maintain customer power plants under our LTSAs. The revenue and cost of our LTSAs in the
fiscal years ended October 31, 2010, 2009 and 2008, were as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2010 |
|
|
2009 |
|
|
2008 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Revenue |
|
$ |
6,850 |
|
|
$ |
5,015 |
|
|
$ |
4,222 |
|
Costs |
|
|
(20,774 |
) |
|
|
(19,386 |
) |
|
|
(24,151 |
) |
|
|
|
|
|
|
|
|
|
|
Costs in Excess of revenue |
|
$ |
(13,924 |
) |
|
$ |
(14,371 |
) |
|
$ |
(19,929 |
) |
|
|
|
|
|
|
|
|
|
|
In fiscal 2008, our five-year fuel cell stack went into production and was placed in service during
fiscal 2009, extending the expected life by two years. Service agreements related to power plants
that have the five-year stack design are not expected to require a stack change to continue to meet
minimum operating levels although we have limited operating experience with these products. Power
plants that do not have the new design may require a stack replacement and we expect to continue to
incur costs for stack changes as the older three-year stacks reach end of life.
Power purchase agreements
Under the terms of our PPAs, customers agree to purchase power from our fuel cell power plants at
negotiated rates, generally for periods of five to ten years. Electricity rates are generally a
function of the customers current and future electricity pricing available from the grid. As owner
of the power plants, we are responsible for all operating costs necessary to maintain, monitor and
repair the power plants. Under certain agreements, we are also responsible for procuring fuel,
generally natural gas, to run the power plants. The assets, including
fuel cell power plants, are carried at book value which approximates fair value based on our
estimates of future revenues and expenses. Should actual results differ from our estimates, our
results of operations could be negatively impacted. We are not required to produce minimum amounts
of power under our PPA agreements and we have the right to terminate PPA agreements by giving
written notice to the customer, subject to certain exit costs.
104
Other
We are involved in legal proceedings, claims and litigation arising out of the ordinary conduct of
our business. Although we cannot assure the outcome, management presently believes that the result
of such legal proceedings, either individually, or in the aggregate, will not have a material
adverse effect on our consolidated financial statements, and no material amounts have been accrued
in our consolidated financial statements with respect to these matters.
Note 17. Supplemental Cash Flow Information
The following represents supplemental cash flow information:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year Ended October 31, |
|
|
|
2010 |
|
|
2009 |
|
|
2008 |
|
Cash Interest Paid |
|
$ |
241 |
|
|
$ |
264 |
|
|
$ |
101 |
|
Supplemental disclosure of non-cash investing and financing activities: |
|
|
|
|
|
|
|
|
|
|
|
|
Common stock issued for employee annual incentive bonus |
|
|
|
|
|
|
1,076 |
|
|
|
1,050 |
|
Note 18. Quarterly Information (Unaudited see accompanying accountants report)
Selected unaudited financial data for each quarter of fiscal years 2010 and 2009 is presented
below. We believe that the information reflects all normal recurring adjustments necessary for a
fair presentation of the information for the periods presented.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
First |
|
|
Second |
|
|
Third |
|
|
Fourth |
|
|
Full |
|
|
|
Quarter |
|
|
Quarter |
|
|
Quarter |
|
|
Quarter |
|
|
Year |
|
Year ended October 31, 2010 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Revenues |
|
$ |
14,616 |
|
|
$ |
16,587 |
|
|
$ |
18,873 |
|
|
$ |
19,701 |
|
|
$ |
69,777 |
|
Loss on operations |
|
|
(14,269 |
) |
|
|
(15,436 |
) |
|
|
(12,559 |
) |
|
|
(12,101 |
) |
|
|
(54,365 |
) |
Net loss |
|
|
(14,718 |
) |
|
|
(15,978 |
) |
|
|
(13,114 |
) |
|
|
(12,516 |
) |
|
|
(56,326 |
) |
Preferred stock dividends |
|
|
(802 |
) |
|
|
(800 |
) |
|
|
(799 |
) |
|
|
(800 |
) |
|
|
(3,201 |
) |
Net loss to common shareholders |
|
|
(15,434 |
) |
|
|
(16,682 |
) |
|
|
(13,825 |
) |
|
|
(12,923 |
) |
|
|
(58,864 |
) |
Net loss to common shareholders
per
basic and diluted common share (1) |
|
$ |
(0.18 |
) |
|
$ |
(0.20 |
) |
|
$ |
(0.15 |
) |
|
$ |
(0.11 |
) |
|
$ |
(0.63 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year ended October 31, 2009 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Revenues |
|
$ |
21,723 |
|
|
$ |
22,864 |
|
|
$ |
23,017 |
|
|
$ |
20,412 |
|
|
$ |
88,016 |
|
Loss on operations |
|
|
(19,435 |
) |
|
|
(18,395 |
) |
|
|
(14,487 |
) |
|
|
(14,048 |
) |
|
|
(66,365 |
) |
Net loss |
|
|
(19,919 |
) |
|
|
(19,080 |
) |
|
|
(14,915 |
) |
|
|
(14,760 |
) |
|
|
(68,674 |
) |
Preferred stock dividends |
|
|
(802 |
) |
|
|
(802 |
) |
|
|
(802 |
) |
|
|
(802 |
) |
|
|
(3,208 |
) |
Net loss to common shareholders |
|
|
(20,721 |
) |
|
|
(19,882 |
) |
|
|
(15,717 |
) |
|
|
(15,562 |
) |
|
|
(71,882 |
) |
Net loss to common shareholders
per basic and diluted common share (1) |
|
$ |
(0.30 |
) |
|
$ |
(0.29 |
) |
|
$ |
(0.21 |
) |
|
$ |
(0.20 |
) |
|
$ |
(0.99 |
) |
|
|
|
(1) |
|
The full year net loss to common shareholders basic and diluted share may not equal the sum
of the quarters due to weighting of outstanding shares. |
105
Note 19. Subsequent Events
Registered Direct Offering
On January 10, 2011 we announced entry into a definitive agreement with an institutional investor
to sell an aggregate of 10,160,428 units at a negotiated price of $1.87 per unit, with each unit
consisting of (i) one share of its common stock, par value $0.0001 per share (Common Stock) and
(ii) one warrant to purchase 1.0 share of Common Stock, in a registered direct offering for gross
proceeds of $19.0 million. The net proceeds from the sale of the units, after deducting the
placement agent fees and other estimated offering expenses, will be approximately $17.8 million.
We intend to use the proceeds from this offering for product development, project financing,
expansion of manufacturing capacity, and general corporate purposes.
The warrants have an exercise price of $2.29 per share and are exercisable beginning on the date
that is six months and one day after the closing date and will expire twenty one months after
issuance. Additionally, FuelCell Energy will obtain the right, subject to certain conditions, to
require the investor to purchase up to 10.0 million additional shares approximately nine months
after the initial closing date of the transaction. The sale price for the additional shares will
be based on a fixed ten percent discount to a volume weighted average price (VWAP) measurement at
the time FuelCell Energy exercises the option. FuelCell Energy cannot require the investor to
purchase more than $20 million of additional shares.
The offering closed on January 13, 2011. Lazard Capital Markets LLC served as the sole placement
agent for the offering.
Series 1 Preferred Share Obligation
As previously disclosed, the Companys wholly owned subsidiary (FCE Ltd) had a $12.5 million
obligation originally due to Enbridge on December 31, 2010. The Company and Enbridge have been in
negotiations to modify certain terms of the Series 1 preferred share agreement, and have agreed to
extend the payment deadline to January 31, 2011 to continue these negotiations. Under the existing
terms, FCE Ltd. has the option of meeting this obligation through a cash payment or with
unregistered shares of FuelCell Energy, Inc. common stock. The Company is a guarantor of FCE Ltds
obligations to Enbridge. Enbridge is currently negotiating new terms that, as proposed, may require
payments in excess of those we believe we are obligated to pay. While the Company intends to
achieve the most favorable outcome in light of its obligations under the Series 1 preferred
shares, it can not presently predict the final terms of any agreement with Enbridge.
This obligation relates to dividends accrued on the series 1 preferred stock acquired in the 2003
acquisition of Global Thermoelectric, Inc (GTI). This obligation has been reported in temporary
equity on the balance sheet as redeemable preferred stock of subsidiary. The Company acquired
Global Thermoelectric due to their expertise in solid oxide fuel cell technology. At the time of
the acquisition, Enbridge owned preferred shares in GTI. Refer also to Note 11 of the Consolidated
Financial Statements.
Revolving Credit Facility
In January 2011, the Company entered into a $5.0 million revolving credit facility with JPMorgan
Chase Bank, N.A. and the Export-Import Bank of the United States. The credit facility is to be
used for working capital to finance the manufacture and production and subsequent export sale of
the Companys products or services. The agreement has a one year term with renewal provisions.
The outstanding principal balance of the facility will bear interest, at the option of the Company
of either the one-month LIBOR plus 1.5 percent or the prime rate of JP Morgan Chase. The facility
is secured by certain working capital assets and general intangibles, up to the amount of the
outstanding facility balance.
106
Item 9. CHANGES IN AND DISAGREEMENTS WITH ACCOUNTANTS ON ACCOUNTING AND FINANCIAL DISCLOSURE
None.
Item 9A. CONTROLS AND PROCEDURES
Disclosure Controls and Procedures.
The Company maintains disclosure controls and procedures, which are designed to provide reasonable
assurance that information required to be disclosed in the Companys periodic SEC reports is
recorded, processed, summarized and reported within the time periods specified in the SECs rules
and forms, and that such information is accumulated and communicated to its principal executive
officer and principal financial officer, as appropriate, to allow timely decisions regarding
required disclosure.
We carried out an evaluation, under the supervision and with the participation of our principal
executive officer and principal financial officer, of the effectiveness of the design and operation
of our disclosure controls and procedures as of the end of the period covered by this report.
Based on that evaluation, the Companys principal executive officer and principal financial officer
have concluded that the Companys disclosure controls and procedures were effective to provide
reasonable assurance that information required to be disclosed in the Companys periodic SEC
reports is recorded, processed, summarized and reported within the time periods specified in the
SECs rules and forms, and that such information is accumulated and communicated to its principal
executive officer and principal financial officer, as appropriate, to allow timely decisions
regarding required disclosure.
Managements Annual Report on Internal Control Over Financial Reporting.
We, as members of management of FuelCell Energy, Inc., and its subsidiaries (the Company), are
responsible for establishing and maintaining adequate internal control over financial reporting.
The Companys internal control over financial reporting is a process designed to provide reasonable
assurance regarding the reliability of financial reporting and the preparation of financial
statements for external purposes in accordance with generally accepted accounting principles in the
United States of America. Internal control over financial reporting includes those policies and
procedures that:
|
|
|
Pertain to the maintenance of records that in reasonable detail accurately and fairly
reflect the transactions and dispositions of the assets of the Company; |
|
|
|
Provide reasonable assurance that transactions are recorded as necessary to permit
preparation of financial statements in accordance with generally accepted accounting
principles of the United States of America, and that receipts and expenditures of the
Company are being made only in accordance with authorizations of management and directors
of the Company; and |
|
|
|
Provide reasonable assurance regarding prevention or timely detection of unauthorized
acquisition, use or disposition of the Companys assets that could have a material effect
on the financial statements. |
Under the supervision and with the participation of management, including our principal executive
and financial officers, we assessed the Companys internal control over financial reporting as of
October 31, 2010, based on criteria for effective internal control over financial reporting
established in Internal Control Integrated Framework, issued by the Committee of Sponsoring
Organizations of the Treadway Commission (COSO). Based on this assessment, we have concluded
that the Company maintained effective internal control over financial reporting as of October 31,
2010 based on the specified criteria.
107
Changes In Internal Control Over Financial Reporting.
There have been no changes in the Companys internal controls over financial reporting during the
most recent fiscal quarter that have materially affected, or are reasonably likely to materially
affect, our internal control over financial reporting.
Item 9B. OTHER INFORMATION
None.
PART III
Item 10. DIRECTORS, EXECUTIVE OFFICERS AND CORPORATE GOVERNANCE
Information required under this Item is incorporated by reference to the Companys 2010 Proxy
Statement to be filed with the SEC within 120 days from fiscal year end.
Item 11. EXECUTIVE COMPENSATION
Information required under this Item is incorporated by reference to the Companys 2010 Proxy
Statement to be filed with the SEC within 120 days from fiscal year end.
|
|
|
Item 12. SECURITY OWNERSHIP OF CERTAIN BENEFICIAL OWNERS AND MANAGEMENT AND RELATED STOCKHOLDER
MATTERS |
Information required under this Item is incorporated by reference to the Companys 2010 Proxy
Statement to be filed with the SEC within 120 days from fiscal year end.
Item 13. CERTAIN RELATIONSHIPS AND RELATED TRANSACTIONS, AND DIRECTOR INDEPENDENCE
Information required under this Item is incorporated by reference to the Companys 2010 Proxy
Statement to be filed with the SEC within 120 days from fiscal year end.
Item 14. PRINCIPAL ACCOUNTING FEES AND SERVICES
Information required under this Item is incorporated by reference to the Companys 2010 Proxy
Statement to be filed with the SEC within 120 days from fiscal year end.
108
PART IV
Item 15. EXHIBITS AND FINANCIAL STATEMENT SCHEDULES
The following documents are filed as part of this report:
|
1. |
|
Financial Statements See Index to Consolidated Financial Statements at Item 8 of the
Annual Report on Form 10-K. |
|
2. |
|
Financial Statement Schedules Supplemental schedules are not provided because of the
absence of conditions under which they are required or because the required information is
given in the financial statements or notes thereto |
|
3. |
|
Exhibits The following exhibits are filed as part of, or incorporated by reference
into, this Annual Report on Form 10-K. |
EXHIBITS TO THE 10-K
|
|
|
|
Exhibit No. |
|
Description |
|
|
|
|
3.1
|
|
|
Certificate of Incorporation of the Registrant, as amended, July 12,
1999 (incorporated by reference to exhibit of the same number contained
in the Companys Form 8-K dated September 21, 1999) |
|
|
|
|
3.1.1
|
|
|
Certificate of Amendment of the Certificate of Incorporation of the
Registrant, dated October 31, 2003 (incorporated by reference to exhibit
of the same number contained in the Companys Form 8-K dated November 4,
2003) |
|
|
|
|
3.2
|
|
|
Restated By-Laws of the Registrant, dated July 13,1999 (incorporated by
reference to exhibit of the same number contained in the Companys Form
8-K dated September 21, 1999) |
|
|
|
|
4
|
|
|
Specimen of Common Share Certificate (incorporated by reference to
exhibit of the same number contained in the Companys Annual Report on
Form 10K/A for fiscal year ended October 31, 1999) |
|
|
|
|
4.1
|
|
|
Securities Purchase Agreement dated as of February 7, 2007, by and
between FuelCell Energy, Inc. and POSCO Power (incorporated by reference
to exhibit of the same number contained in the Companys Form 8-K dated
February 20, 2007) |
|
|
|
|
4.2
|
|
|
Schedule A to Articles of Amendment of FuelCell Energy, Ltd., setting
forth the rights, privileges, restrictions and conditions of Class A
Cumulative Redeemable Exchangeable Preferred Shares (incorporated by
reference to exhibit of the same number contained in the Companys Form
10-Q for the period ended January 31, 2009). |
|
|
|
|
4.3
|
|
|
Certificate of Designation for the 5% Series B Cumulative Convertible
Perpetual Preferred Stock (Liquidation Preference $1,000) (incorporated
by reference to Exhibit 3.1 contained in the Companys Form 8-K, dated
November 22, 2004). |
|
|
|
|
4.4
|
|
|
Securities Purchase Agreement dated as of June 9, 2009, by and between
FuelCell Energy, Inc. and POSCO Power (incorporated by reference to
exhibit 4.01 contained in the Companys Form 8-K, dated November 2,
2009). |
|
|
|
|
10.1
|
|
|
** Alliance Agreement between FuelCell Energy, Inc. and POSCO Power,
dated as of February 7, 2007 (incorporated by reference to exhibit of
the same number contained in the Companys Form 10-Q/A for the period
ended January 31, 2009). |
109
EXHIBITS TO THE 10-K
|
|
|
|
Exhibit No. |
|
Description |
|
|
|
|
10.2
|
|
|
** Technology Transfer, License and Distribution Agreement between
FuelCell Energy, Inc. and POSCO Power, dated as of February 7, 2007
(incorporated by reference to exhibit of the same number contained in
the Companys Form 10-Q/A for the period ended January 31, 2009). |
|
|
|
|
10.3
|
|
|
Loan agreement, dated April 29, 2008, between the Company and the
Connecticut Development Authority (incorporated by reference to exhibit
of the same number contained in the Companys Form 10-Q for the period
ended January 31, 2009). |
|
|
|
|
10.4
|
|
|
** Stack Technology Transfer and License Agreement dated as of October 27,
2009, by and between FuelCell Energy, Inc. and POSCO Power (incorporated
by reference to exhibit 10.1 of the Companys Form 8-K, dated November
2, 2009). |
|
|
|
|
10.5
|
|
|
** Contract for the Supply of DFC Modules and DFC Components dated as of
June 9, 2009, by and between FuelCell Energy, Inc. and POSCO Power
(incorporated by reference to exhibit 10.2 of the Companys Form 8-K,
dated November 2, 2009). |
|
|
|
|
10.21
|
|
|
*FuelCell Energy, Inc. 1988 Stock Option Plan (incorporated by reference
to exhibit of the same number contained in the Companys Amendment No. 1
to its Registration Statement on Form S-1 (File No. 33-47233) dated June
1, 1992) |
|
|
|
|
10.36
|
|
|
*The FuelCell Energy, Inc. Section 423 Stock Purchase Plan
(incorporated by reference to exhibit of the same number contained in
the Companys 10-KSB for fiscal year ended October 31, 1994 dated
January 18, 1995) |
|
|
|
|
10.41
|
|
|
*Amendment No. 2 to the FuelCell Energy, Inc. Section 423 Stock Purchase
Plan (incorporated by reference to exhibit of the same number contained
in the Companys 10-Q for the period ended April 30, 1996 dated June 13,
1996) |
|
|
|
|
10.42
|
|
|
*Amendments to the FuelCell Energy, Inc. 1988 Stock Option Plan
(incorporated by reference to exhibit of the same number contained in
the Companys 10-Q for the period ended April 30, 1996 dated June 13,
1996) |
|
|
|
|
10.48
|
|
|
*Employment Agreement between FuelCell Energy, Inc. and the Chief
Financial Officer, Treasurer and Secretary, dated October 5, 1998
(incorporated by reference to exhibit of the same number contained in
the Companys 10-K for the fiscal year ended October 31, 1998) |
|
|
|
|
10.54
|
|
|
*The FuelCell Energy, Inc. 1998 Equity Incentive Plan (incorporated by
reference to exhibit of the same number contained in the Companys 10-Q
for the period ended July 31, 1998) |
|
|
|
|
10.55
|
|
|
Lease agreement, dated March 8, 2000, between the Company and Technology
Park Associates, L.L.C. (incorporated by reference to exhibit of the
same number contained in the Companys 10-Q for the period ended April
30, 2000) |
|
|
|
|
10.56
|
|
|
Security agreement, dated June 30, 2000, between the Company and the
Connecticut Development Authority (incorporated by reference to exhibit
of the same number contained in the Companys 10-Q for the period ended
July 31, 2000) |
|
|
|
|
10.57
|
|
|
Loan agreement, dated June 30, 2000, between the Company and the
Connecticut Development Authority (incorporated by reference to exhibit
of the same number contained in the Companys 10-Q for the period ended
July 31, 2000) |
|
|
|
|
10.60
|
|
|
* Employment Agreement, dated January 12, 2006, between R. Daniel Brdar
(incorporated by reference to exhibit of the same number contained in
the Companys 8-K dated January 17, 2006). |
|
|
|
|
10.61
|
|
|
Export loan agreement dated January
4, 2011, between the Company and
JPMorgan Chase Bank, N.A. |
|
|
|
|
10.62
|
|
|
Security Agreement dated January 4,
2011, between the Company and JPMorgan Chase Bank, N.A. |
|
|
|
|
10.63
|
|
|
Intracreditor Subordination and
Confirmation Agreement made and effective as of January 4, 2011 by
JPMorgan Chase Bank, N.A. |
|
|
|
|
10.64
|
|
|
Promissory Note dated January 4,
2011, between the Company and JPMorgan Chase Bank, N.A. |
|
|
|
|
10.65
|
|
|
* Employment Agreement, dated
January 28, 2010 between FuelCell Energy, Inc. and Arthur Bottone,
Senior Vice President, Chief Commercial Officer. |
110
EXHIBITS TO THE 10-K
|
|
|
|
Exhibit No. |
|
Description |
|
|
|
|
14
|
|
|
Code of Ethics applicable to the Companys principal executive officer,
principal financial officer and principal accounting officer.
(incorporated by reference to exhibit of the same number contained in
the Companys 10-K for the year ended October 31, 2003) |
|
|
|
|
21
|
|
|
Subsidiaries of the Registrant |
|
|
|
|
23.1
|
|
|
Consent of Independent Registered Public Accounting Firm |
|
|
|
|
31.1
|
|
|
Certification of Chief Executive Officer pursuant to Section 302 of the
Sarbanes Oxley Act of 2002 |
|
|
|
|
31.2
|
|
|
Certification of Chief Financial Officer pursuant to Section 302 of the
Sarbanes Oxley Act of 2002 |
|
|
|
|
32.1
|
|
|
Certification of Chief Executive Officer pursuant to Section 906 of the
Sarbanes Oxley Act of 2002 |
|
|
|
|
32.2
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Certification of Chief Financial Officer pursuant to Section 906 of the
Sarbanes Oxley Act of 2002 |
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* |
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Management Contract or Compensatory Plan or Arrangement |
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** |
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Confidential Treatment has been granted for portions of this document |
111
SIGNATURES
Pursuant to the requirements of Section 13 or 15(d) of the Securities Exchange Act of 1934, the
registrant has duly caused this report to be signed on its behalf by the undersigned, thereunto
duly authorized on January 14, 2011.
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FUELCELL ENERGY, INC. |
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/s/ R. Daniel Brdar |
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Dated:
January 14, 2011 |
Chairman, President and Chief Executive Officer |
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Pursuant to the requirements of the Securities Exchange Act of 1934, this report has been
signed below by the following persons on behalf of the registrant and in the capacities and on the
dates indicated.
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Signature |
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Capacity |
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Date |
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/s/ R. Daniel Brdar
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Chairman, President, and Chief Executive Officer
(Principal
Executive Officer)
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January 14, 2011 |
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/s/ Joseph G. Mahler
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Senior Vice President, Chief Financial Officer,
Corporate Secretary and Treasurer
(Principal
Accounting and Financial Officer)
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January 14, 2011 |
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/s/ Richard A. Bromley
Richard A. Bromley
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Director |
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January 13, 2011 |
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/s/ James H. England
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Director |
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January 10, 2011 |
112
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Signature |
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Capacity |
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Date |
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/s/ James D. Gerson |
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Director
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January 7, 2011 |
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/s/ Thomas L. Kempner |
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Director
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January 7, 2011 |
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/s/ William A. Lawson
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Director
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January 7, 2011 |
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/s/ George K. Petty |
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Director
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January 9, 2011 |
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/s/ John A. Rolls
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Director
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January 6, 2011 |
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/s/ Togo Dennis West Jr.
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Director
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January 7, 2011 |
113
INDEX OF EXHIBITS
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Exhibit 10.61
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Export loan Agreement dated January
4, 2011, between the Company and
JPMorgan Chase Bank, N.A. |
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Exhibit 10.62
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Security Agreement dated January 4,
2011, between the Company and JPMorgan Chase Bank, N.A. |
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Exhibit 10.63
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Intracreditor Subordination and
Confirmation Agreement made and effective as of January 4, 2011 by
JPMorgan Chase Bank, N.A. |
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Exhibit 10.64
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Promissory Note dated January 4,
2011, between the Company and JPMorgan Chase Bank, N.A. |
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Exhibit 10.65
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* Employment Agreement, dated
January 28, 2010 between FuelCell Energy, Inc. and Arthur Bottone,
Senior Vice President, Chief Commercial Officer. |
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Exhibit 21
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Subsidiaries of the Registrant |
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Exhibit 23.1
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Consent of Independent Registered Public Accounting Firm |
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Exhibit 31.1
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CEO Certification pursuant to Section 302 of the Sarbanes-Oxley Act of 2002 |
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Exhibit 31.2
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CFO Certification pursuant to Section 302 of the Sarbanes-Oxley Act of 2002 |
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Exhibit 32.1
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CEO Certification pursuant to Section 906 of the Sarbanes-Oxley Act of 2002 |
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Exhibit 32.2
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CFO Certification pursuant to Section 906 of the Sarbanes-Oxley Act of 2002 |
114