UNITED
STATES
SECURITIES
AND EXCHANGE COMMISSION
Washington,
D.C. 20549
FORM
10-K
(Mark
One)
x |
ANNUAL
REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE
ACT OF
1934
|
For
the
fiscal year ended: October
31, 2006
OR
o |
TRANSITION
REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE
ACT OF
1934
|
For
the
transition period from ___________ to ___________
Commission
File Number: 1-14204
FUELCELL
ENERGY, INC.
(Exact
name of registrant as specified in its charter)
Delaware
|
06-0853042
|
(State
or other jurisdiction of
|
(I.R.S.
Employer
|
incorporation
or organization)
|
Identification
Number)
|
3
Great Pasture Road
|
|
Danbury,
Connecticut
|
06813
|
(Address
of principal executive offices)
|
(Zip
Code)
|
Registrant’s
telephone number, including area code
(203) 825-6000
N/A
(Former
name, former address and former fiscal year, if changed since last
report)
Securities
registered pursuant to Section 12(b) of the Act.
None.
Securities
registered pursuant to Section 12(g) of the Act:
Common
Stock, $0.0001 Par Value
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 x
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 the registrant’s 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, or a non-accelerated filer. See definition of “accelerated
filer and large accelerated filer” in Rule 12b-2 of the Exchange Act (Check
one):
Large
Accelerated Filer o
|
Accelerated
Filer x
|
Non-accelerated
Filer o
|
Indicate
by check mark whether the Registrant is a shell company (as defined in Rule
12b-2 of the Act).
Yes
o No x
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 registrant’s 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
The
aggregate market value of voting and non-voting common equity held by
non-affiliates of the registrant known to us as of April 28, 2006 was
approximately $587.5 million, which is based on the closing price of $13.13
on
April 28, 2006. On
January 10, 2007 there were 53,169,234 shares
of
common stock of the registrant issued and outstanding.
DOCUMENTS
INCORPORATED BY REFERENCE Certain
information contained in the registrant’s definitive proxy statement relating to
its forthcoming 2007 Annual Meeting of Shareholders to be filed not later than
120 days after the end of registrant’s fiscal year ended October 31, 2006 is
incorporated by reference in Part III of this Annual Report on Form
10-K.
FUELCELL
ENERGY, INC.
INDEX
|
Description
|
Page
Number
|
Part
I
|
|
|
Item
1
|
Business
|
6
|
Item 1A
|
Risk
Factors
|
27
|
Item
2
|
Properties
|
38
|
Item
3
|
Legal
Proceedings
|
38
|
Item
4
|
Submission
of Matters to a Vote of Security Holders
|
38
|
|
|
|
Part
II
|
|
|
Item
5
|
Market
for the Registrant’s Common Equity and Related Stockholder
Matters
|
39
|
Item
6
|
Selected
Financial Data
|
46
|
Item
7
|
Management’s
Discussion and Analysis of Financial Condition and Results of
Operations
|
48
|
Item 7A
|
Quantitative
and Qualitative Disclosures about Market Risk
|
65
|
Item
8
|
Consolidated
Financial Statements and Supplementary Data
|
66
|
Item
9
|
Changes
In and Disagreements with Accountants on Accounting and Financial
Disclosure
|
102
|
Item 9A
|
Controls
and Procedures
|
102
|
Item
9B
|
Other
Information
|
104
|
|
|
|
Part
III
|
|
|
Item
10
|
Directors
and Executive Officers of the Registrant
|
|
Item
11
|
Executive
Compensation
|
|
Item
12
|
Security
Ownership of Certain Beneficial Owners and Management and Related
Stockholder Matters
|
|
Item
13
|
Certain
Relationships and Related Transactions
|
|
Item
14
|
Principal
Accountant Fees and Services
|
|
|
|
|
Part
IV
|
|
|
Item
15
|
Exhibits,
Financial Statement Schedules and Reports on Form 8-K
|
105
|
|
|
|
Signatures
|
|
109
|
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 schedule for our fuel cell technology and products, future
funding under government research and development contracts, the expected cost
competitiveness of our technology, and the timing and availability of products
under development. 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 introduction, 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, and competition, as well as other risks contained under
Item 7 “Management’s Discussion and Analysis of Financial Condition and Results
of Operations - Factors That May Affect Future Results” 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 products or technology, once developed, will be 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 “Factors That May Affect Future
Results” in Item 7 of this Report.
We
define
distributed generation as small (typically 50 megawatts or less) electric
generation plants (combustion-based such as engines and turbines as well as
non-combustion-based such as fuel cells) located at or near the end use
customer. 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.
As
used
in this Report, all degrees refer to Fahrenheit (“F”) and kilowatt and megawatt
numbers designate nominal or rated capacity of the referenced power plant.
As
used in this Annual Report, “efficiency” or “electrical efficiency” means the
ratio of the electrical energy (“AC”) 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
the 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; “kilowatt” (“kW”) means 1,000 watts; “megawatt” (“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 “Btu” is equal to one
million British Thermal Unit (the amount of heat necessary to raise one pount
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 - Fuel
gas
produced in biomass digesters employing bacterial and controlled oxygen
environment from municipal, industrial or commercial water treatment
facilities.
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 operating 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 operating hours since commercial acceptance date (mutually agreed upon
time period when our 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.
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.
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.
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 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. There
are currently 23 states and the District of Columbia with RPS programs that
mandate a certain percentage of their electricity be generated from renewable
resources. Fuel cells using biomass fuels qualify as renewable power generation
technology in all of these states, and certain states (Connecticut, Hawaii,
Maine, New York and Pennsylvania) specify that fuel cells operating on natural
gas are eligible under these standards.
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.
Item
1. BUSINESS
OVERVIEW
FuelCell
Energy is a world leader in the development and manufacture of fuel cell power
plants for ultra-clean, efficient and reliable electric power
generation. Our products are designed to meet the 24/7 baseload power needs
of commercial, industrial, government and utility customers. To date our
products have generated over 150 million kilowatt hours of electricity and
we
have units operating at over 50 locations around the world.
We
have
been developing fuel cell technology since our founding in 1969. Our core
carbonate fuel cell products (“Direct FuelCell®
or
DFC®
Power
Plants”) offer stationary power generation applications for customers. In
addition to our current commercial products, we continue to develop our next
generation of carbonate fuel cell and hybrid products as well as planar solid
oxide fuel cell (“SOFC”) technology with our own and government research and
development funds.
Our
proprietary carbonate DFC power plants electrochemically (meaning without
combustion) produce electricity directly from readily available hydrocarbon
fuels, such as natural gas and biomass fuels. Customers buy fuel cells to
improve reliability and reduce cost and emissions.
We
believe that compared to other power generation technologies, our products
offer
significant advantages including:
· |
Reliable
24/7 baseload power,
|
· |
Ultra-clean
(e.g. virtually zero emissions) quiet
operation,
|
· |
Lower
cost power generation, and
|
· |
The
ability to site units locally and provide high temperature heat for
cogeneration applications.
|
Typical
customers for our products include manufacturers, mission critical institutions
such as correction facilities and government installations, hotels and customers
who can use waste or byproducts of their operations for fuel such as breweries,
food processors and waste water treatment facilities.
With
increasing demand for renewable and ultraclean power options, and increased
volatility and uncertainty in electric markets, our customers gain control
of
power generation economics, reliability and emissions. Our fuel cells offer
flexible siting and easy permitting.
Our
DFC
power plants are protected by 46 U.S. and 74 international patents and we have
also submitted 38 U.S. and 123 international patent applications.
Current
Market Dynamics
According
to the Energy Information Administration, worldwide electricity demand in 2003
was approximately 15 billion kWh and is expected to more than double by 2030.
The market for clean power is strong and growing. Wind and solar installations
are expanding rapidly with increasing market demand for renewable and ultraclean
power generation. These solutions offer intermittent power generation, in
effect, when the wind blows and when the sun is shining. Our ultra-clean
products are a 24/7 baseload power solution for this market, a key requirement
for commercial, industrial and utility customers.
The
market is beginning to recognize the advantages of stationary fuel cell power.
Volatile fuel and energy prices, the ratification of the Kyoto Protocol by
over
160 countries since 2005, and worldwide efforts to minimize CO2 emissions,
greenhouse gases and other harmful emissions with mandates for significant
increases in clean electric power generation, are placing greater emphasis
on
ultra-clean, high efficiency distributed generation products. Electric
generation without combustion significantly reduces harmful pollutants such
as
NOX, SOX and particulates. Higher fuel efficiency results in lower emissions
of
carbon dioxide, a major contributor of harmful greenhouse gases and also results
in less fuel needed per kWh of electricity generated and Btu of heat produced,
thereby reducing exposure to volatile natural gas costs and minimizing operating
costs.
In
2006,
customers ordered 5.05 MW and we shipped 6.75 MW of our products. All orders
during the year were multi-unit or MW sized products in our target
markets. Custmers included wastewater treatment facilities,
universities, hotels, industrial operations and natural gas pipeline
applications. In addition to expanding our markets, we
have
taken a number of steps to ensure that we are prepared to address RPS market
opportunities. We engineered a lower cost product for multi-megawatt
configurations. We also initiated production process improvements to increase
the efficiency of our manufacturing and commissioning
operations.
Although
we made significant progress in 2006 executing our business plan to reduce
costs
and increase market share, current market dynamics have resulted in a slow
developing sales environment. For example, sales in California, Connecticut
and
Japan have been impacted by volatile fuel prices and lagging electric rates.
In
California and Connecticut, this situation has recently improved as higher
fuel
prices are being incorporated into electric rates. Product sales are also
impacted by the current regulatory and political environment. Exit fees, standby
charges and interconnect fees continue to limit distributed generation,
including fuel cells, in many markets.
We
expected Connecticut’s Project 100 to move forward in early 2006, but it was
delayed nearly a year moving through the regulatory cycle. This program is
now
moving forward and our partners submitted approximately 99 MW of bids in
December 2006 in response to the Connecticut Clean Energy Fund Request for
Proposals (“RFP”). Site selections are expected to be announced in March
2007.
Positive
regulatory actions were enacted in California and by the U.S. government. In
California, the legislature recently passed AB32, a sweeping greenhouse gas
bill
that requires businesses to reduce greenhouse gas emissions 25% by 2020. This,
together with existing environmental regulations and incentives as well as
the
flexibility inherent in siting our products, create a highly favorable market
for fuel cells. In December 2006, a bill was approved that extends the
Investment Tax Credit through 2008. These credits apply to projects that create
electricity from fuel cells, wind, geothermal, solar and biomass, as well as
other alternative energy initiatives and enhance the economics of theses
projects.
Value
Proposition of Our Products
Customers
buy our fuel cells for reliability, cost and environmental demands. There are
currently strong incentive programs in our target markets including California
and the Northeast in the U.S., Korea and Japan in Asia and Germany in Europe
that make the cost of clean power solutions including fuel cells, wind and
solar
competitive. We believe that with the continued cost reduction of our products
and with increased volume that our products are expected to be cost competitive
on an unsubsidized basis against the grid and other distributed generation
products, such as engines.
Value
Proposition - On-Site Power. Stationary
fuel cell power plants are an economical alternative to utility-provided power
and other distributed generation in on-site power applications. Customers can
often produce power with our products for less than the local utility price
or
other competing distributed generation products. Customers gain the added
benefits of quiet operations,
improved reliability and lower emissions.
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 or less, depending on location
and
application. We believe this is competitive with grid-delivered electricity
and
other distributed generation products in the regions in which we compete. We
believe that tougher emission standards will increase the cost of competing
distributed generation products.
Value
Proposition - Utility or RPS.
States
seeking to secure cleaner energy sources are setting standards that require
utilities provide a certain amount of their electricity from renewable sources
such as solar, wind, biomass-fueled technologies, and fuel cells. There are
currently 23 states and the District of Columbia that have instituted Renewable
Portfolio Standards legislation. These markets in the U.S. alone represent
a
potential for an estimated 25,000 MW. Fuel cells using biomass fuels qualify
as
renewable power generation technology in all of these
states, with five states specifying that fuel cells operating on
natural gas are eligible for these initiatives.
As
more
intermittent power generation sources including wind and solar are added to
the
electric grid, states and utilities are looking to balance this generation
with
alternative ultraclean products that can provide power 24/7. Stationary
fuel cell power plants can provide 24/7 power to meet the needs of utilities
trying to implement RPS initiatives. Fuel cell power plants can also provide
power to grid-constrained areas incrementally without large transmission and
distribution investments.
Business
Strategy
Our
business strategy is to expand our leadership position in key markets, build
multi-megawatt markets and continue to reduce the costs of our products. A
product mix weighted more heavily with MW-class products is our fastest path
to
achieve profitability. In 2007, our focus will be as follows:
Build
on our leadership position in vertical and geographic markets -
· |
California
–
We are the
fuel cell market leader in California where high electricity costs
and
stringent environmental regulations make our products a compelling
value
proposition for customers. California extended
its Self-Generation Incentive Program (SGIP) to 2012. The SGIP provides
annual incentives, at least $80 million in 2007, for which our fuel
cell
products are eligible.
|
· |
Asia
–
Japan and
Korea continue to be among our best markets due to high electricity
cost,
environmental regulations and incentives for fuel cells. In 2006,
Korea
enacted its first-ever subsidies to promote renewable energy technologies
as part of a national carbon dioxide reduction effort. Fuel cells
are
eligible for the recovery of 28 cents per kWh and 50 MW of generation
will
qualify for these funds which are intended to drive the installation
of
megawatt-class power plants.
|
· |
Europe
–
The European Union and member countries have various initiatives
underway
to promote clean energy. New and expanding incentives in Germany
and
elsewhere could encourage more sales in 2007 and we are well positioned
to
capitalize on this growth.
|
Build
Multi-Megawatt Markets –
RPS
Markets – RPS programs mandate a certain percentage of their electricity be
generated from renewable and ultra-clean resources. Our multi-MW products in
installations from 2 to 50 MWs and our pipelind applications are well suited
to
operate in these markets. Near term opportunities, which we are pursuing in
these markets are:
· |
Connecticut
–
FuelCell Energy and its partners submitted nearly 99 MW of multi-megawatt
bids to the Connecticut Clean Energy Fund (CCEF) in December 2006.
CCEF
has announced that its project selections will be announced in March
2007.
|
· |
Natural
Gas Pipeline Applications –
FuelCell Energy sold a 1.2 MW fuel cell power plant to Enbridge,
Inc. for
inclusion in a Direct FuelCell-Energy Recovery Generation™ (DFC-ERG™)
system that generates ultra-clean electricity while recovering energy
normally lost during natural gas pipeline operations. The DFC-ERG
opens
major new market opportunities for the Company worldwide - in North
America the initial market is estimated to be 200-300 MW. We are
working
with Enbridge, Inc. to capture opportunities in this
market.
|
Cost
Reduction –
· |
FuelCell
Energy will continue its cost out initiatives to deliver the most
competitive and environmentally friendly products in the market.
Our cost
reduction efforts are now in their fourth year and we have reduced
product
costs by over 70 percent since the program began. As a result, our
largest
product (the 2.4 MW DFC3000) has a product cost of $3,250/kW, which
is
close to market clearing prices and could benefit from additional
volume
that could reduce the cost another 10 to 20 percent in 2007 without
further design changes.
|
· |
The
DFC300MA and DFC1500MA are targeted to achieve 20 percent cost reductions
in 2007 through improvements in strategic sourcing, value engineering
and
operations in 2007.
|
· |
We
are also working toward additional power output increases and improvements
to stack life which are expected to result in lower costs across
the
entire product line.
|
At
a
sustained annual order and production volume of approximately 35 MW to 50 MW,
depending on product mix, geographic location and other variables such as fuel
prices, we believe we can reach gross margin breakeven. We believe that net
income break-even can be achieved at a sustained annual order and volume
production of approximately 75-100 MW. Since the cost of our 2.4 MW product
is
currently at market clearing prices in certain target markets such as
Connecticut, profitability could be achieved on lower production volumes if
product mix trends more toward MW and multi-MW orders.
PRODUCTS
Direct
FuelCell® (DFC®) Power Plants
Our
core
products, the DFC300MA, DFC1500MA and DFC3000, are currently rated in capacity
at 300 kW, 1.2 MW and 2.4 MW, respectively and are designed for applications
up
to 50 MW. Our products are designed to meet the baseload power requirements
of a
wide range of customers including wastewater treatment plants (municipal, such
as sewage treatment facilities, and industrial, such as breweries and food
processors), hotels, manufacturing facilities, universities, hospitals,
telecommunications/data centers, government facilities, as well as grid support
applications for utility customers. Our DFC power plants can be part of a
total onsite power generation solution for customers, with our high efficiency
products providing the baseload power with grid-delivered electricity and
intermittent power, such as solar, or less efficient combustion-based equipment
providing peaking and load following energy needs. Our products are also ideal
to meet the needs of utilities and RPS mandates.
A
fuel
cell chemically converts a hydrocarbon fuel into electricity without fuel
combustion. The primary byproducts of the fuel cell are heat, water and carbon
dioxide. There is virtually no SOX or NOX emissions. A fuel cell power plant
can
be thought of as having two basic segments: the fuel cell stack module, the
part
that actually produces the electricity, and the balance of plant (“BOP”), which
includes various fuel handling and processing equipment, such as pipes and
blowers, and electrical interface equipment such as inverters to convert the
DC
output of the fuel cell to AC.
Conventional
fossil fuel based 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, which is used to rotate a steam turbine generating additional
electricity. The combustion process typically creates emissions of SOX and
NOX,
carbon monoxide, soot and other air pollutants.
The
following table shows industry estimates of the electrical efficiency, operating
temperature, expected capacity range and certain other operating characteristics
of the principal types of fuel cells being developed for commercial
applications:
Fuel
Cell Type
|
|
Electrolyte
|
|
Electrical
Efficiency
%
|
|
Operating
Temperature
oF
|
|
Expected
Capacity
Range
|
|
By-Product
Heat Use
|
PEM
|
|
Polymer
Membrane
|
|
30-35
|
|
180
|
|
5
kW to
250
kW
|
|
Warm
Water
|
Phosphoric
Acid
|
|
Phosphoric
Acid
|
|
35-40
|
|
400
|
|
50
kW to
200
kW
|
|
Hot
Water
|
Carbonate
(Direct
FuelCell®)
|
|
Potassium/Lithium
Carbonate
|
|
45-57
|
|
1200
|
|
250
kW to
3
MW and larger
|
|
Hot
water or High Pressure
Steam
|
Solid
Oxide (Tubular)
|
|
Stabilized
Zirconium dioxide Ceramic
|
|
45-50
|
|
1800
|
|
100
kW to
3
MW
|
|
Hot
water or
High
Pressure
Steam
|
Solid
Oxide (Planar)
|
|
Stabilized
Zirconium dioxide Ceramic
|
|
40-60
|
|
1200-1600
|
|
3
kW to 1 MW and larger
|
|
Hot
water or High Pressure Steam
|
Our
carbonate fuel cell, known as the Direct FuelCell, operates at approximately
1200°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 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 by-product heat energy (700°F)
that can be harnessed for combined heat and power (“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 wastewater treatment
gas, by reforming the fuel inside the fuel cell to produce hydrogen. We believe
that 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 wastewater treatment gas have
infrastructures that are already established. Consequently, our DFC products
do
not need to wait for the development of the hydrogen infrastructure for
continued commercialization.
Our
Direct FuelCells have been operated using a variety of hydrocarbon fuels,
including natural gas, methanol, diesel, biogas, coal gas, coal mine methane
and
propane. Our commercial DFC power plants currently can achieve an
electrical efficiency of between 45 percent and 47 percent. Depending on
location, application and load size, a co-generation configuration can reach
an
overall energy efficiency of between 70 percent and 80
percent.
MARKETS
We
have
established a leading position in the sale of fuel cell power plants and
strengthened our position in 2006 by improving our product performance and
availability, reducing costs for our MW and sub-MW products, and expanding
repeatable markets for our DFC products.
· |
Our
cumulative fleet availability continues to exceed 90 percent. Many
of our
units are achieving greater than 95 percent availability at customer
sites.
|
· |
Seven
new orders were received totaling 5.05 MW, with six orders of 600
kW or
more and 2 orders of at least 1 MW, in key repeatable markets. Our
distribution partner, Marubeni, has also committed, by paying a 10
percent
deposit, to another 6 MW of fuel cell products.
|
Certain
of our markets and applications are developing at a faster rate as evidenced
by
the chart below. Through October 31, 2006, we have installed an aggregate of
18.0 MW and have 10.05 MW in backlog. Geographically, our leading markets are
California and Japan, which account for 70 percent of our orders to date. Our
leading applications are wastewater treatment facilities and hotels.
There
has
been increasing support for fuel cell technology. Specific examples include
the
following:
· |
The
first tax incentives for fuel cell power plants at the U.S. federal
level
were enacted in August 2005 and provide for a 30 percent investment
tax
credit (“ITC”) up to $1,000/kW of total project costs, as well as 5 year
accelerated depreciation. The bill to extend the ITC through 2008
passed
in December 2006.
|
· |
State
level RPS programs are in place in some states which call for renewable
and ultra-clean electric power generation. For example, Connecticut
is
requiring that 100 MW of renewable/ultra-clean power generation be
installed by 2008 and a total of approximately 400 MW by 2010. Currently,
23 states and the District of Columbia have RPS laws on their books
of
which five specifically make fuel cells using natural gas eligible
for credits.
|
· |
There
are also other subsidy programs that benefit fuel cell market penetration
in key markets which we compete. Examples include the California
Self
Generation Incentive Program which provides annual subsidies greater
than
$80 million for renewable and ultra-clean distributed generation
technologies and a Korean Renewable Portfolio Agreement whereby
the Korean
government and nine state-run utility companies have agreed to
invest over
1 trillion won (approximately $1 billion U.S.) in a renewable energy
research and development
effort.
|
Distributed
Generation Markets
We
believe distributed generation can be a more cost-effective solution than
traditional grid-delivered electricity and other distributed generation
technologies:
· |
Provides
better economics.
Distributed generation avoids transmission and distribution system
investment, reduces line losses, can use the heat by-product from
onsite
power generation and offers the ability to control energy cost economics
through fuel flexibility.
|
· |
Increases
reliability by locating power closer to the end
user.
Onsite power generation bypasses the congested transmission and
distribution system, increasing electrical
reliability.
|
· |
Eases
congestion in the transmission and distribution
system.
Each kW of onsite power generation removes the same amount from the
transmission and distribution system, thereby easing congestion that
can
cause power outages and hastening the grid recovery after electrical
infrastructure problems have been
resolved.
|
· |
Eliminates
T&D investments and provides greater capacity utilization in less
time.
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 generating plants and transmission and
distribution systems (often 36 months or longer) which require more
extensive siting and right of way approvals. Siting distributed generation
can defer or avoid altogether massive T&D investment such as unpopular
above ground high voltage lines or even more expensive underground
high
voltage lines.
|
· |
Enhances
security.
By locating smaller, incremental power plants in dispersed locations
closer to energy consumers, distributed generation can reduce dependence
on a vulnerable centralized electrical
infrastructure.
|
Our
DFC
power plants specifically provide the following attributes that provide an
advantage over other distributed technologies of similar size:
· |
Higher
operational efficiency.
Our DFC power plants currently achieve electrical efficiencies of
45 to 47
percent and have the potential to reach an electrical efficiency
of 57
percent and an overall energy efficiency of 70 to 80 percent for
CHP
applications. This is significantly greater than the fuel efficiency
of
competing fuel cell and combustion-based technologies of similar
size and
results in a lower cost per kWh over the life of the power
plant.
|
· |
Lower
emissions.
Our DFC power plants have lower emissions of carbon dioxide, and
significantly lower emissions of other harmful pollutants, such as
NOX,
SOX and particulate matter, than conventional combustion-based power
plants. They have been designated ultra-clean by the California Air
Resources Board (“CARB”), and our DFC products are certified to CARB 2007
emissions standards. Emissions of fuel cell power plants versus
traditional combustion-based power plants as compiled by the DOE/National
Energy Technology Laboratory and company product specification sheets
are
as follows:
|
|
|
Emissions
(Lbs. Per MWh)
|
|
|
|
NOX
|
|
SO2
|
|
CO2
|
|
Average
U.S. Fossil Fuel Plant
|
|
|
4.200
|
|
|
9.210
|
|
|
2,017
|
|
Microturbine
(60 kW)
|
|
|
0.490
|
|
|
0.000
|
|
|
1,862
|
|
Small
Gas Turbine (250 kW)
|
|
|
0.467
|
|
|
0.000
|
|
|
1,244
|
|
Fuel
Cell, Single Cycle (DFC)
|
|
|
0.016
|
|
|
0.000
|
|
|
967
|
|
· |
Utilize
multiple fuels.
Our DFC power plants can use many fuel sources, such as natural gas,
industrial and municipal wastewater treatment gas and coal gas (escaping
gas from active and abandoned coal mines as well as synthesis gas
processed from coal), thereby enhancing independence from imported
oil and
allowing customers to have fuel flexibility. Our DFC power plants
can
provide our customers with an option to choose the cheapest
alternative.
|
· |
Provide
end users with greater control of their energy costs.
Due
to the high efficiency of our DFC power plants, end users would typically
select to have their firm, 24/7 baseload power needs provided by
our
ultra-clean products. The cost of utility provided power continues
to rise
and is subject to large, unpredictable increases. Generating on-site
power
with hedged fuel and known generating costs resulting from the operation
of a DFC power plant give customers a predictable component of their
operations that can be budgeted, and
controlled.
|
Geographic
Markets
We
are
focused on markets where local business conditions, incentives and
regulations make it advantageous for customers to purchase our
products.
North
America – California
California
has maintained a leadership position in environmental policy. Executive
Order S-3-05 enacted in 2005 set state reduction levels for greenhouse gasses
and the California Air Resources Board Standard for 2007 (“CARB 2007”) set
limits for other emissions (i.e. NOX, SOX, particulates, etc.). These
regulations help promote technologies such as fuel cells for clean distributed
power generation. Our DFC power plants meet these strict emissions requirements
and have been designated as an ultra-clean distributed generation technology.
As
a result, customers have access to certain incentive funding for the purchase
of
our DFC power plants and are exempt from exit fees and stand-by charges. In
addition, end users of fuel cell power plants are eligible to sell back unused
power to publicly owned utilities at wholesale or generation-based
rates.
The
California Self Generation Incentive Program provides annual incentives of
at least $80 million for renewable and ultra-clean distributed generation
technologies. Our DFC power plants operating on natural gas are eligible for
a
subsidy of up to $2,500/kW and our DFC power plants operating on biomass
renewable fuels, such as anaerobic digester gas from wastewater treatment
facilities, are eligible for a subsidy of up to $4,500/kW. This program has
been
extended through 2012.
North
America – U.S. RPS and Northeastern States
States
seeking to secure cleaner energy sources are setting standards that require
that
utilities provide a certain amount of their electricity from renewable sources
such as solar, wind or other biomass-fueled technologies, as well as
‘ultra-clean’ fuel cells. Currently, 23 states and the District of Columbia have
RPS laws on their books. Fuel cells using biomass fuels qualify as renewable
power generation technology in all of these states, and five states specify
fuel cells operating on natural gas as eligible for these initiatives.
Connecticut
has enacted legislation requiring the state’s utility distribution companies to
procure approximately 400 MW of clean energy sources by 2010. In addition,
100
MW of generation from renewable technologies must be in place by 2008 (“Project
100”). Fuel cell power plants principally manufactured in Connecticut have an
advantage against other project competition as they are entitled
to the available air emissions credits and tax credits attributable to the
project and no less than 50 percent of the energy credits in the Class I
renewable energy credits attributable to the project. For other Class I
renewable energy technologies, these credits are allocated to the utility to
be
used to reduce costs to ratepayers.
New
York
has adopted an energy policy requiring up to 3,700 MW of new generation from
renewable technology by 2013. New York State issued its first request for
proposal (“RFP”) under this program in 2004 and is expected to issue additional
requests for proposals in 2007 focused on customer sited projects as well as
large utility size projects.
North
America – Canada
Canada
has ratified the Kyoto Protocol and is also focused on reducing emissions such
as NOX and SOX in selected regions. Our distribution partner, Enbridge Inc.,
is
currently seeking to have our products included in a portfolio to replace more
than 500 MW of coal power to help meet the Canadian Government’s Kyoto Protocol
carbon dioxide and other emissions reduction commitments. These projects would
compete with other low impact generation technologies (like solar and some
wind)
for funding through the country’s Cdn.$250 million Sustainable Development
Technology Corporation Program and other similar Federal and Provincial
programs. In addition, we are jointly developing with Enbridge the DFC ERG
product, a specifically designed product for natural gas pipeline applications,
with a market potential of over 40 MW in the greater Toronto area and over
200
MW in the Northeast U.S. and California.
Asia
– Japan
The
key
drivers for clean distributed power generation in Japan are high electricity
prices, the lack of significant domestic natural energy sources, and the
adoption of the Kyoto Protocol. In response, Japanese companies are maximizing
the energy efficiency of their operations and reducing the emissions of
greenhouse gases. Additionally, government regulations require the use of
biomass fuels from wastewater treatment facilities. The high efficiency of
our
products can provide lower energy costs and reduced carbon dioxide emissions,
and the fuel flexibility of our products allows operation using biomass fuel.
These factors create several market opportunities in Japan.
Japan
has
instituted a number of incentive programs. The recently introduced Biomass
Nippon program administered by the Ministry of Agriculture, Forestry, and
Fisheries provides 33 percent incentive funding for local governments or private
companies installing power generation facilities. The Ministry of Land,
Infrastructure and Transport (“MLIT”) provides 55 percent subsidies to local
governments who install equipment to generate power at wastewater treatment
facilities. A national RPS program for the power generation sector was adopted
in 2004 with initial targets of approximately 3,500 MW by 2010. Our DFC products
qualify under these programs.
Working
with our distribution partner, Marubeni Corporation, we have installed or in
backlog 7.25 MW for the Japanese market. Applications include wastewater
treatment and manufacturing for several well known companies such as Sharp
Electronics, Seiko Epson and Kirin Brewery. As grid electricity continues to
be
costly in Japan, and our product costs continue to decline, we expect Japan
to
be a strong market for our fuel cells.
Asia
– Korea
In
2004,
the Korean government identified fuel cells as one of the 10 economic growth
engines for the Korean economy. POSCO, our distribution partner, was selected
to
develop and commercialize large stationary fuel cell power plants. The Korean
government’s goal is to install 300 stationary fuel cell power plants, sized 250
kW to 1 MW, by 2012, and has designated $1.6 billion to support this effort.
The
Korean government and nine state-run utility companies have agreed to invest
over 1 trillion won (approximately $1 billion U.S.) in a renewable energy
research and development effort designated as the Renewable Portfolio Agreement
(“RPA”). Korea’s Ministry of Commerce, Industry and Energy has stated that the
RPA signed seeks to generate enough new power from renewable sources to replace
approximately 1.6 million barrels of crude oil. During 2006, Korea followed
up
these initiatives by instituting a $0.28/kWh incentive to encourage end-users
to
use power from renewable sources.
POSCO
and
the Korea South-East Power Company (“KOSEP”) have announced an alliance to
market and develop fuel cell power plants based on our DFC products as a means
to fulfill the RPA requirements As part of this alliance agreement, KOSEP has
recently installed one of our DFC300MA units at its plant in Bundang, Gyeonggi
province. Currently, we have three units operating in Korea at Chosun
University, Tancheon Sewage Treatment Plant and at POSCO’s Research Institute of
Science and Technology (RIST) in Pohang, POSCO itself, representing 1 MW of
installations in Korea. We believe that our partnership with POSCO combined
with
the $0.28/kWh incentive makes this Korea an excellent market for our fuel
cells.
Europe
The
European Union (“EU”) imports 50 percent of its energy and projects that 65
percent of its total energy requirements will be imported by 2030. Interest
in
nuclear power, which currently accounts for 13 percent of generating capacity,
has declined amid safety concerns in recent years, with several EU counties
recently announcing a phase-out of their nuclear programs. The emphasis remains
on reducing carbon dioxide emissions and grid-connected CHP projects are
encouraged. Under the Kyoto Protocol, the EU is obligated to reduce its
greenhouse gas emissions by 8 percent from 1990 levels by 2008 to 2012. In
a report dated January 10, 2007, the Commission of the European Communities
recommended reducing greenhouse gas emissions by 20 to 30 percent of 1990 levels
by 2020. The report cited three reasons: (1) energy production accounts for
80 percent of all greenhouse gas emissions in Europe, (2) such a reduction
will limit Europe's exposure to volatile energy prices, and (3) this plan could
lead to more innovative power generation technology and more
jobs.
MTU
CFC
Solutions GmbH, our partner, has exclusive distribution rights for our DFC
products in Europe. Their strategy is to seed the market with sub-MW units,
and
lobby the EU and German government for increased subsidies to further market
penetration, and then expand production as costs approach market clearing
prices. Several subsidy programs have been implemented. In January 2005, the
EU
instituted the EU Emissions Trading Scheme (ETS), under which approximately
12,000 large industrial plants in the EU have been able to buy and sell permits
to release carbon dioxide into the atmosphere. The ETS enables companies
exceeding individual carbon dioxide emissions targets to buy allowances from
greener ones. In Germany, a CHP Law was enacted in 2002 that provides a
€0.0511/kWh
subsidy payable for 10 years for grid-connected CHP power plants, up to 2 MW.
MTU CFC believes that these subsidies along with others that are being
contemplated will help to increase sales in the European market.
Applications
Within
these geographic markets, we are targeting applications that we believe have
the
best potential for repeatable business for our products:
· |
Wastewater
treatment plants.
For wastewater treatment applications, the methane generated from
the
anaerobic gas digestion process is used as fuel for the DFC power
plant,
which generates the electricity to operate the wastewater treatment
equipment at the facility or for the grid. Through December 31,
2006, we have installed or have in backlog a total of 5.85 megawatts.
Representative installations
include:
|
· |
City
of Tulare, California (digester gas, 750
kW)
|
· |
Sierra
Nevada Brewing Company, California (Natural / digester gas, 1
MW)
|
· |
LA
County Sanitation Palmdale Waste Water Treatment Plant (digester
gas, 250
kW)
|
· |
Kirin
Brewery, Japan (Natural gas/ propane, 250
kW).
|
· |
Hotels.
Hotels, with their stable baseload heat and power demand profile,
are
ideal applications for our DFC power plants. A 300-room suburban
hotel
typically has a baseload power requirement of 250 kW. Through December
31,
2006, we have installed or have in backlog 3.50 MW. Representative
installations include:
|
· |
Sheraton
San Diego Hotel & Marina, California (1.5
MW).
|
· |
Westin
San Francisco Airport, California (500
kW).
|
· |
Sheraton
New York Hotel and Towers, New York (250
kW).
|
· |
Industrial
– Manufacturing.
Manufacturing companies are also a great application for our combined
heat
and power fuel cell systems. Through December 31, 2006, we have installed
or have in backlog 4.0 MW. Representative installations
include:
|
· |
Gills
Onions, California (500 kW)
|
· |
NGK,
Korea (Ceramics kiln, 250 kW).
|
· |
Institutional
– Universities.
Universities are excellent combined heat and power applications as
many
have their own independent grid. In the U.S., there are over 1,000
universities with an average generating capacity of approximately
7 MW.
Through December 31, 2006, we have installed or have in backlog 2.5
MW.
Representative installations
include:
|
· |
California
State University, Northridge (1
MW)
|
· |
State
University of New York - Environmental Science and Forestry, New
York (250
kW)
|
· |
Pohang
University, Korea (250 kW).
|
· |
Institutional
– Hospitals.
Hospitals are an excellent combined heat and power application, with
a
critical need for reliable, baseload heat and power for 24/7 operation
and
the grid for backup. A 300-bed hospital has a typical baseload power
requirement of 2 MW. Through December 31, 2006, we have installed
or have
in backlog 1.25 MW. Representative installations include (all 250
kW):
|
· |
Chosen
University Hospital,
Korea
|
· |
Gruendstadt
Clinic, Germany
|
· |
Bad
Berka Hospital, Germany.
|
· |
Mission-Critical
- Telecommunications/Government. Reliability
is a key driver for applications at government facilities and
telecommunications/data centers. Through December 31, 2006, we have
installed or have in backlog 4.5 MW. Representative installations
include:
|
· |
San
Francisco Post Office, California (Post Office, 250
kW)
|
· |
NTT
Sendai, Japan (Telecommunications, 250
kW)
|
· |
Santa
Rita Correctional Facility, California (Prison, 1 MW).
|
· |
Grid
Support.
Through December 31, 2006, we have installed or have in backlog 1.75
MW.
Representative installations include (all 250
kW):
|
· |
Los
Angeles Headquarters of Water and Power,
California
|
· |
Salt
River Project, Arizona
|
· |
RWE
Energy Park, Germany
|
· |
Natural
Gas Pipeline. The
DFC-ERG power plant is an ultra-clean combined cycle generation system
that incorporates our Direct FuelCell power plant and an unfired
expansion
gas turbine for natural gas pipeline letdown stations. These are
stations
in the gas distribution system where gas pressure is reduced from
the
transmission pressure (>500 psi) to local distribution pressures
(typically 30 – 60 psi). This pressure reduction is usually done through a
pressure letdown valve, and because the gas is cooled by the pressure
reduction, it often needs to be heated by combustion-based boilers
to
prevent freezing. The DFC-ERG combines an expansion turbine and a
DFC fuel
cell in an integrated system. The expansion turbine replaces the
let-down
valve, producing power in the process. The combustion boiler is replaced
by waste heat recovered from the DFC, which makes additional power.
The
high efficiency of the DFC combined with the power recovered from
the
let-down turbine and the fuel saved by heat recovery result in a
system
efficiency of approximately 60 percent. Enbridge, Inc. has estimated
the
North American market for the DFC-ERG to be between 200 and 300
MW.
|
· |
Enbridge,
Inc. has ordered a 1.2MW
plant from us which will be used in a DFC-ERG
configuration.
|
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 product.
OEM
Partners
MTU
CFC Solutions GmbH
(“MTU
CFC”), headquartered in Ottobrunn, Germany, has been a co-developer of our DFC
technology since 1989. Our sub-MW power plant is a collaborative effort using
our DFC technology and the Hot Module®
BOP
designed by MTU CFC. As an OEM developer of stationary fuel cell power plants,
MTU CFC assembles and stacks the DFC components that we sell to them and then
adds their mechanical and electrical balance of plants for ultimate sale to
their customers. In 2006, EQT (a Sweden-based private equity firm),
acquired MTU CFC’s parent company, MTU Friedrichshafen GmbH, from
DaimlerChrysler. There are currently sub-MW fuel cell power plant installations
at eleven locations in Europe. The parent company of MTU CFC (MTU
Friedrichshafen GmbH) owns approximately 2.7 million shares of our common stock
and is represented on our Board of Directors.
Marubeni
Corporation.
We have installed or have in backlog 8.25 MW in Japan and we currently have
a
commitment from Marubeni for an additional 6 MW. In 2006, units were installed
at Tokyo Gas’ new research and development center at Tsurumi, Tokyo, where it is
undergoing evaluation and demonstration prior to potentially being offered
by
Tokyo Gas to its customers via their industrial gas sales division. Four
DFC300MA units, totaling 1 MW in output, were also installed at Sharp Ltd.’s
“super-green” factory in Kameyama Prefecture, where Sharp manufactures LCD
screens for its flat-panel television displays. Notably, the 1 MW fuel cell
installation provides base load power to the facility, while 5 MW of Sharp’s own
photovoltaic (PV) modules provide peaking power. This is an example of the
way
in which DFC systems can combine with solar power to provide a total solution
for ultra-clean renewable power for environmentally leading
companies.
In
2006,
world-leading ceramics manufacturer NGK Inc. installed one of our DFC300MA
systems at its headquarters building and main factory in Nagoya, where NGK
manufactures catalytic converters for Toyota Corp. and others. In 2007, the
DFC300MA will be integrated with the company’s ceramics kiln in a proprietary
configuration to boost the overall energy efficiency of the plant. Other
installations in Japan include the Tokyo Super Eco Town Project and Kyoto Eco
Energy Project, both of which convert food wastes into useful energy; the Kirin
Brewery near Tokyo; the City of Fukuoka municipal wastewater treatment facility;
Japex’s Katakai natural gas gathering station located in the Niigata Prefecture;
and two units to Epson’s Quartz Device Division in the City of Ina, Nagano
Prefecture, Japan.
Marubeni
invested $10 million in us in 2001 through the purchase of approximately 268,000
shares of our common stock. In 2004, we issued warrants to purchase
1,000,000 shares of our common stock to Marubeni in conjunction with a revised
distribution agreement. As part of these warrant agreements, the warrants vest
in separate tranches once Marubeni has ordered totals of between 5 MW and 45
MW
of our products. As of October 31, 2006, 800,000 of these warrants had expired.
The exercise price of the remaining 200,000 outstanding warrants (which are
not
vested) is $18.73 per share and the warrants will expire April 2007, if not
earned and exercised sooner.
POSCO.
In
Since
November 2004, we and Marubeni Corp. signed an agreement with POSCO to
distribute and package DFC power plants in Korea. POSCO has purchased four
250
kW DFC300MA power plants through Marubeni, which are located at the Research
Institute of Science and Technology (RIST) in Pohang University, Chosun
University Hospital, and Tancheon Wastewater Treatment Facility in Seoul, and
at
the KOSEP power generating station at Bundang. POSCO has extensive experience
in
power plant project development, building over 2,400 megawatts of power plants,
equivalent to 3.7 percent of Korea’s national capacity, for its various
facilities. POSCO is a world leader in the materials industry and is one of
the
world’s largest producers of steel.
Caterpillar,
Inc.
DFC units have been shipped to several commercial customers of Caterpillar
including: a municipal wastewater treatment application for the Sanitation
Districts of Los Angeles County in Palmdale, California; and the State
University of New York College of Environmental Science and Forestry.
Caterpillar is currently offering our DFC products to its customers and has
stated it intends to offer its own branded fuel cell power plant based on our
technology.
Enbridge
Inc.
Enbridge, a leader in energy transportation and distribution in North America
and internationally, expanded our market development agreement to include
current DFC product distribution in the US as well as Canada, and to include
the
new DFC-ERG™ product in North America. In 2005, we issued warrants to Enbridge
to purchase up to 1,000,000 shares of our common stock in conjunction with
an
amended distribution agreement. The warrants vest on a graduated scale based
on
the total number of megawatts contained in product orders and the timing of
when
such orders are generated by Enbridge. In October 2006, Enbridge placed an
order
for the first DFG ERGTM,
which
resulted in vesting of 30,000 warrants with an exercise price of $9.89. The
expiration date of these vested warrants is October 31, 2008. The exercise
prices of the remaining non-vested 970,000 warrants range from $9.89 to $11.87
per share and the expiration dates range from June 30, 2008 to June 30, 2010,
if
not earned and exercised sooner.
Energy
Service Company Distribution Partners
We
have
five Energy Service Company distribution partners:
Alliance
Power, Inc.
Alliance Power is a developer of distributed generation facilities ranging
in
size from 1 MW to 49 MW. Alliance has been focusing its efforts in California
on
customers requiring DFC power plants for baseload combined heat and power
applications from 500 kW to 1.5 MW. In 2006, Alliance Power secured orders
totaling 3.85 MW, including projects for California State University,
Northridge, Gills Onions, the City of Tulare and a California
resort.
Chevron
Energy Solutions.
We entered into an agreement with Chevron Energy Solutions (“Chevron”), a
subsidiary of ChevronTexaco, in December 2001, to jointly market and sell DFC
power plants, with initial projects targeted for the northeastern U.S. and
California. Chevron has sold and installed a 1 MW DFC1500MA power plant in
California to Alameda County for the Santa Rita Correctional Facility and a
DFC300MA power plant for the U.S. Postal Service’s San Francisco Processing and
Distribution Center.
Linde
Group We
entered into a non exclusive agreement with The Linde Group, a worldwide market
leader in industrial gases and engineering, to sell and market Direct
FuelCell(R) (DFC(R)) power plants worldwide except where FuelCell Energy already
has granted exclusive distribution agreements. Linde will focus initially on
DFC
opportunities in North America that fit into its overall strategy of developing
sustainable energy solutions and providing low-carbon distributed generation
solutions to industrial, commercial and governmental customers, with longer
term
plans to leverage this relationship into other geographies where Linde has
market leadership.
LOGANEnergy
Corp.
We
entered into an agreement with LOGANEnergy Corp. (“LOGAN”) in July 2004 to
jointly market and sell DFC power plants. In 2005, we received two orders from
LOGAN totaling 750 kW for government training facilities in California - 500
kW
for a U.S. Marine Base at Camp Pendleton and the U.S. Marine Corps Air Ground
Center at Twentynine Palms.
PPL
Energy Plus.
PPL
Energy Plus (“PPL”), a subsidiary of PPL Corporation, has purchased and
installed DFC power plants at three Starwood Resorts properties (Sheraton Edison
and Sheraton Parsippany in New Jersey and Sheraton New York Towers in
Manhattan); one unit at Ocean County College in New Jersey; and one unit at
a
Pepperidge Farm Bakery in Bloomfield, Conn.
Customer
Partners
We
have
partnered directly with certain customers who have installed our products.
These
customer partners have the option to negotiate arrangements for the sale,
distribution and service of our DFC power plants upon completion of the
project.
Our
longest standing customer partner relationship is with the Los Angeles
Department of Water and Power (“LADWP”), the largest municipal utility in the
U.S. with 640,000 water customers and 1.4 million electric customers.
LADWP participated with us on our 2 MW Santa Clara Demonstration Project in
1996-1997 and currently has three DFC 300A power plant installations
(grid-connected units at its Main Street facility, headquarters building, and
a
wastewater treatment plant installation at Terminal Island).
Competition
We
compete on the basis of our products’ reliability, fuel efficiency,
environmental considerations and cost. We believe that our DFC carbonate
fuel cell offers competitive and environmental advantages over most other fuel
cell designs and other combustion-based technologies for stationary baseload
power generation.
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.;
UTC Fuel Cells; and Plug Power), phosphoric acid fuel cells (UTC Fuel Cells)
and
solid oxide fuel cells (Siemens Westinghouse Electric Company; Cummins; SOFCo;
General Electric; Delphi; 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 Asia,
Ishikawajima Harima Heavy Industries is active in developing carbonate fuel
cells. In Europe, a company in Italy, Ansaldo Fuel Cells, is actively
engaged in carbonate fuel cell development and is a potential competitor. MTU
CFC and its partners have been the most active in Europe.
Other
than fuel cell developers, we must also compete with such companies as
Caterpillar, Cummins Inc., and Detroit Diesel Corporation (a subsidiary of
DaimlerChrysler AG), which manufacture more mature combustion-based equipment,
including various engines and turbines, and have more established manufacturing,
distribution, operating and cost features. Significant competition may
also come from gas turbine companies like General Electric, Ingersoll-Rand
Company Limited, Solar Turbines Incorporated 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 made efforts
to extend these advantages to smaller sizes. We believe, however, that
these smaller gas turbines will not be able to match our fuel efficiency or
favorable environmental characteristics.
POWER
PURCHASE AGREEMENTS
Power
purchase agreements (PPAs) are a common arrangement in the energy industry,
whereby a customer purchases energy from an owner and operator of the power
generation equipment. A number of our partners enter into PPAs with end use
customers, such as Marubeni in Japan and PPL in the U.S., where they purchase
DFC power plants from us, own and operate the units, and recognize revenue
as
energy is sold to the end user.
We
have
seeded the market with a number of Company funded PPAs to penetrate key target
markets and develop operational and transactional experience. To date, we have
funded the development and construction of certain fuel cell power plants sited
near customers in California, and own and operate 3 MW of assets through PPA
entities in which we have an 80% ownership interest. As we enter in to multi-MW
projects in the RPS markets and with the benefit of the federal investment
tax
credit and accelerated depreciation in the Energy Policy Act of 2005 we believe
future PPAs will attract third party financing.
MANUFACTURING
AND COST REDUCTION
We
have
established 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 modules that are currently
delivered to our test and conditioning facilities in Danbury, Connecticut.
Sub-MW modules are combined and tested with the balance of plant to complete
our
power plants at the customer site. Our MW modules for the DFC1500MA and DFC3000
are tested and conditioned in Danbury and then shipped to the customer site
for
final testing with an assembled balance of plant.
Our
manufacturing, testing and conditioning facilities have equipment in place
for a
production capacity of 50 MW per year. We believe manufacturing capacity can
be
increased to 125 - 150 MW within our existing Torrington facility through the
addition of parallel production lines and additional machinery. We also have
additional land surrounding our Torrington facility, on which we could expand
to
400 MW of annual production of our repeating fuel cell components. Expansion
of
our manufacturing facilities beyond 50 MW would also require new facilities
for
the fuel cell stack and module assembly, test and conditioning which could
be
deployed regionally. These regional assembly, test and conditioning facilities
are expected to provide additional cost savings as they will reduce shipping
costs, enhance delivery times and improve customer service. Our current
production volume is 10 MW which will be adjusted depending on customer demand
and the emergence of the RPS market.
Our
2 MW
Santa Clara ‘proof-of-concept’ project in 1996-1997 cost more than $20,000/kW to
produce. In 2003, we shipped our first commercial product, a DFC300 to the
Kirin
Brewery which cost more than $10,000/kW. At that time, we implemented our
commercial cost-out program hiring additional engineers who focused on reducing
the total life cycle costs of our power plants. Since 2003, they have made
significant progress primarily through value engineering our products and
increasing the power output by 20%. Our
current manufactured cost of approximately $3,250 /kW on our multi-MW power
plant, $4,300/kW on our MW plant and $4,800/kW for the sub-MW product. Reducing
product cost is essential for us to further penetrate the market for our
high
temperature fuel cell products. Cost reductions will lessen and/or eliminate
the
need for incentive funding programs that are currently available to allow
our
product pricing to compete with grid-delivered power and other distributed
generation technologies, and are critical to us attaining
profitability.
In
2006,
we primarily focused our cost saving efforts on our multi-MW product, the
DFC3000. Significant savings came from “value engineering” – developing
lower-cost designs for various elements of the power plant – and improving the
efficiency of the Company’s manufacturing, testing and commissioning processes.
The cost reduction also resulted from the 20 percent increase in power output
in
our DFC products announced in August 2006. By improving thermal management
of
electrochemical activity within the stack, the Company increased the power
output from each cell, which produces more electricity from the same basic
power
plant components.
FuelCell
Energy will continue to emphasize its cost out initiatives to deliver the most
cost efficient and environmentally friendly power generation solutions and
meet
the needs of the emerging RPS markets. In 2007, the DFC300MA and DFC1500MA
are
targeted to achieve another 20 percent cost reduction through improvements
in
strategic sourcing, value engineering and operations. Increased production
volume could also reduce that cost another 10 to 20 percent.
SERVICE
AND CUSTOMER SATISFACTION
Our
service organization offers comprehensive service and maintenance programs
including total fleet management, refurbishment and recycling services, and
complete product support including spare parts inventory. We are offering
service agreements at various levels for one to 13 years, with flexible renewal
options.
FuelCell
Energy has invested in a Service Group organization that offers a complete
service portfolio for FuelCell Energy’s DFC product line. The Service Group’s
primary task is to maintain a high level of service for our end user customers
during the warranty period of the original DFC equipment. In providing the
wide
range of services required to support the fleet during the warranty period,
the
Service Group has developed infrastructure that can be easily extended to
capture revenue as the units in the field enter the period past the warranty
period. In 2006, we achieved revenues of $1.7 million in long-term service
agreements and revenue is expected to grow in the years to come.
In
providing the range of services required to support the fleet during the
warranty and service agreement period, the service organization has developed
infrastructure to support its efforts which includes a 24/7 Call Center and
a
web-based information system network that allows fingertip access to plant
performance data. We have also established regional parts warehouses including
rotable pool of spare stacks, fully equipped regional field service teams,
a
stack repair/refurbishment center, testing and conditioning facilities. All
personnel complete an operator and maintenance technician training program
and
work very closely with the engineering and technology support organizations
to
service our products in the field. This infrastructure has enabled us do
diagnosis issues quickly and maintain strong customer satisfaction.
In
2006,
we improved the availability of our fleet meeting our customers’ expectation for
product performance and availability. We have over 50 units installed at
customer sites throughout the U.S., Asia and Europe. Through December 31,
2006,
we have generated more than 150 million kWhs at customer sites worldwide,
with a
cumulative fleet availability of over 90 percent.
In
2006,
a customer satisfaction survey polling customers that own and operate our
DFC
units in the U.S. and Japan, solicited feedback on all aspects of our products
and services. The Service organization received high ratings from our customers.
The customers polled were extremely pleased with the aftermarket and service
support that they were receiving and believed that the service provided held
exceptional value.
GOVERNMENT
RESEARCH AND DEVELOPMENT CONTRACTS
The
goal
of our research and development efforts is to improve our core DFC products
and
expand our technology portfolio in complementary high temperature fuel cell
systems, such as SOFC. In addition, we are also conducting limited
development work on advanced applications for other fuel cell technologies,
such
as PEM. A significant portion of our research and development has been funded
by
government contracts and is classified as cost of research and development
contracts in our consolidated financial statements. For the fiscal years
ended
2006, 2005 and 2004, total research and development expenses, including amounts
received from the DOE, other government departments and agencies and our
customers, and amounts that have been self-funded, were $22.0 million, $35.0
million and $44.9 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 DOE, the Navy, the Coast
Guard, the Department of Defense, the Environmental Protection Agency, the
Defense Advance Research Projects Agency and the National Aeronautics and
Space
Administration. Government funding, principally from the DOE, provided
approximately 35 percent, 43 percent and 60 percent of our revenue for the
fiscal years ended 2006, 2005 and 2004, respectively. From the inception
of our carbonate fuel cell development program in the mid-1970s to date,
more
than $536 million
has been invested to support the development of our DFC technology. This
includes approximately $355 million from government agencies, with the balance
provided by private entities, utility organizations and licensees.
Significant
programs we are currently working on include:
Carbonate
Fuel Cell Programs
Direct
FuelCell/Turbine.
The
DOE’s Office of Fossil Energy established its Vision 21 Program in 1999 with
the
objective of developing a “21st
Century
Energy Plant” that can generate electricity, heat, clean fuels, chemicals and
hydrogen from a variety of feedstocks such as fossil fuels and biomass with
high
efficiency and low environmental impact. The Company was awarded
a $19.4
million cost-shared contract to develop a fuel cell / turbine hybrid power
plant
under this program.
In
2005,
we completed the fabrication of an alpha sub-MW power plant by the intregration
of a 250kW DFC stack module with a Capstone C60 microturbine. The
microturbine supplements the power produced by the fuel cell, increasing
the
system electrical efficiency. The unit was installed and grid-connected at
the
Billings Clinic in Billings, Montana and started generating power in April
2006.
During approximately 8,000 hours of operation, the
unit
achieved a record-breaking electrical efficiency of 56 percent, surpassing
all
distributed generation technologies in this size range. Emissions testing
of the
DFC/T system demonstrated compliance with the stringent California Air Resources
Board’s CARB ’07 standards.
Subsequent
to the success of the DFC/T field demonstration and following the Company’s
shift to MW scale products, we have initiated the design of a MW-scale hybrid
DFC/T.
Dual
Fuel Testing at CTC.
The
ability to operate highly efficient, pollution-free, distributed-generation
power plants interchangeably on either natural gas or HD-5 grade propane
is of
interest to the U.S. Army and other applications as a way to maintain secure
power for critical power operations. Propane, a
readily
available and transportable fuel that can easily be stored on-site,
can also
be
used
as a primary fuel to
islands, remote sites, national parks, data centers, military bases, hotels,
and
hospitals. In
response to the interest for a fuel flexible power plant, Concurrent
Technologies Corporation (CTC), under contract to the U.S. Army Engineering,
Research and Development Center's Construction Engineering Research Laboratory
(ERDC-CERL), subcontracted with FuelCell Energy (Sept. 2005) to test a DFC300MA
power plant on propane at their Johnstown, Pennsylvania location. The purpose
of
the demonstration was to operate our DFC300MA power plant on HD-5 grade propane
as well as natural gas and to switch rapidly between these fuels. This system
was designed to enable the generation of ultra-clean baseload electricity
even
in situations when fuel supplies are threatened due to natural disaster,
terrorism or repair outages.
This
DFC300MA fuel cell power plant operated on HD-5 propane for eight months
in
2006. During this demonstration period the power plant accumulated over 5,000
hours of operation on propane and natural gas generating more than 700 MW
hours
(MWh) of electricity.
Co-production
of Hydrogen and Electricity using DFC Power Plants
Our
high
temperature DFC power plants produce hydrogen internally from hydrocarbon
fuels,
and then convert it to electricity. These DFC products are capable of
co-production of electricity and hydrogen at potentially attractive costs.
This
value-added proposition is quite attractive for industrial users of hydrogen
in
the near term. It also provides a technology bridge to the hydrogen
infrastructure being developed by DOE for our nation’s energy independence. A
recent DOE-sponsored study performed by Air Products and Chemicals, Inc.
(APCI),
showed that a sub-MW DFC power plant installed at a hydrogen refueling station
for fuel cell vehicles can handle a fleet of approximately 200 cars while
providing enough electricity to power a community of 200 homes.
During
2005, we were selected by Air Products to develop and demonstrate the Next
Generation Hydrogen Energy station. The $10 million cost-shared project,
co-sponsored by DOE, APCI and FCE, will integrate our ultra-clean DFC power
plant and Air Products’ advanced gas separation technology to co-produce
hydrogen and electricity at a vehicle refueling station from one single system
(“DFC-H2”).
The
sub-MW system will be designed to operate on pipeline natural gas and other
renewable fuels such as waste-derived biogas. Air Products estimates that
the
DFC-H2
system
has the potential to be highly efficient and cost competitive with other
conventional technologies. Several locations in California are being evaluated
for the demonstration of the DFC-H2
system,
presently scheduled to be on-stream in late 2007.
We
are
also engaged in technology development of an electrochemical hydrogen separator
(EHS). Under sponsorship of Connecticut Clean Energy Fund, a subscale EHS
stack
was designed, built and delivered to University of Connecticut for demonstration
in February 2006. The EHS stack has accumulated over six months of stable
operation on a variety of test conditions. During 2006, we were selected
by U.S.
Department of Defense to scale-up its solid-state electrochemical hydrogen
separator (EHS) technology to co-produce high purity hydrogen from its DFC
power
plants. The EHS technology is highly modular, “truly green” and promises over 50
percent reduction in the separation cost. EHS has no moving parts, which
leads
to enhanced reliability and higher levels of safety needed for the hydrogen
infrastructure. The technology scale-up during 2007 will focus on laboratory
validation tests of large-area EHS stacks, followed by a sub-megawatt system
demonstration in 2008.
DFC
Marine/Diesel.
We are
continuing development of marine applications for our DFC technology under
contracts to the U.S. Navy. The marine power plants are required to operate
on
liquid fuel including diesel. We have a multi-year contract with the Office
of
Naval Research to develop a 500 kW first generation power plant for
demonstration at the Naval Sea Systems Command facility in Philadelphia.
We have
constructed and verified operation of the balance of plant (BOP) process
equipment for the marine DFC power plant. The BOP has been integrated with
our
commercial DFC module, and the complete power plant is undergoing initial
performance testing in Danbury, Connecticut. Following completion of additional
testing, the plant is expected to be delivered to Philadelphia during the
second
quarter of 2007. This $25.4 million cost-shared project commenced in 2000
and is
a continuation of an earlier $4.6 million contract that completed the conceptual
design and testing of the critical components for the marine fuel cell power
module.
We
expect
that successful demonstration of this project can lead to additional diesel
fuel
cell power plant applications for commercial ships and remote site power
generation.
Solid
Oxide Fuel Cell Programs
SECA
Program
In
September 2006, we completed all the technical requirements for the DOE’s Solid
State Energy Conversion Alliance (“SECA”) Phase I, 3-10 kW solid oxide fuel cell
(“SOFC”) cost reduction program and entered into a new SECA Phase I program for
development of a multi-megawatt SOFC power plant operating on coal syngas
(the
Large Scale Hybrid Program).
Program
technical highlights included demonstration testing of a 3 kW SOFC system
for
over 2,100 hours that successfully met or exceeded all DOE performance metrics
for power output, efficiency and degradation (life). This system was
subsequently shipped to the DOE National Energy Technology Laboratory (“NETL”)
at Morgantown, West Virginia where the unit operated for approximately 1,500
hours confirming the operational results. A factory cost estimate was conducted
based on the 3 kW SOFC system design and bill-of-materials which verified
that
the system cost estimate is less than the DOE SECA program specified phase
I
program metric of $800/kW.
Large
Scale Hybrid
In
February 2006, we were selected by the DOE as a prime contractor for a Phase
I
award to develop a coal-based, multi-megawatt solid oxide fuel cell-based
hybrid
system. The contract was finalized in September 2006. The program’s overall
objective is to develop SOFC technology, fueled by coal synthesis gas (coal
gas)
that will be used in highly-efficient central generation power plant facilities.
The advanced fuel cell-hybrid system will have an overall efficiency of at
least
50 percent in converting energy contained in coal to grid electrical power.
In
contrast, today’s average U.S. coal-based power plant has an electrical
efficiency of approximately 35 percent. In addition, the envisioned SOFC-hybrid
system is expected to separate 90 percent or more of the system’s carbon dioxide
emissions for capture and environmentally safe disposal while being cost
competitive with other baseload power generating technologies.
The
first
phase of this three phase program will focus on SOFC cell and stack technology
scale-up, as well as baseline and proof-of-concept system engineering design
and
analysis. The project will culminate in phase three with the fabrication
and
operation of a multi-MW proof-of-concept SOFC-hybrid power plant at FutureGen,
a
planned DOE demonstration of advanced power systems that emit near-zero
emissions, doubling today's electric generating efficiency, co-produce hydrogen,
and sequester carbon dioxide or
at
another suitable location using coal-derived synthesis gas as the fuel. Phase
I
of the program is a two-year, $36.2 million cost-shared program. If selected
for
subsequent phases, total project funding of approximately $180 million is
anticipated.
We
are
the prime contractor on this program and other team members include: Versa
Power
Systems, Inc., Gas Technology Institute (“GTI”), Nexant, Inc., WorleyParsons
Group Inc., and SatCon Technology Corporation.
GOVERNMENT
REGULATION
We
presently are, and our fuel cell power plants will be, 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 fuel cell 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
DFC power plants, assuming no cogeneration application, is humid flue gas
that
is discharged at a temperature of approximately 700-800° F, water that is
discharged at a temperature of approximately 10-20° F above ambient air
temperatures and carbon dioxide. In light of the high temperature of the
gas
emissions, we are required by regulatory authorities 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 permitted to be discharged into a storm
drain or into the local wastewater system. Lastly, as with any use of
hydrocarbon fuel, the discharge of particulates 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.
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 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. In this regard, we have 46 current U.S. patents and 74 international
patents covering our fuel cell technology (in certain cases covering the
same
technology in multiple jurisdictions). All of the 46 U.S. patents relate
to our
Direct FuelCell technology. We also have submitted 38 U.S. and 123 international
patent applications.
The
patents we have obtained will expire between 2008 and 2024, and the current
average remaining life of our patents is approximately 11.4 years. In 2006,
three new U.S patents were issued. In fiscal 2006, six U.S. patents expired.
The
expiration of these patents has no material impact on our current or anticipated
operations. We also have approximately 30 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 the DOE cooperative agreement. Three of our patents,
which
resulted from government-funded research before January 1988 (when we qualified
as a “small business”), are owned by the U.S. government and have been licensed
to us.
U.S.
patents that we own that resulted from government-funded research are subject
to
the government exercising “march-in” rights. We believe, however, 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.
We
have
two agreements with MTU CFC; a Cell License Agreement and a Balance of Plant
License Agreement. Under our current Cell License Agreement, which has
been extended through December 2009, we license our DFC technology to MTU
CFC
for use exclusively in Europe and the Middle East and non-exclusively in
Africa
and South America. We also sell our DFC components and stacks to MTU CFC
under this agreement. Under the Cell License Agreement, MTU CFC also
granted us an exclusive, royalty-free license to use any of their existing
improvements to our Direct FuelCell that MTU CFC developed as of December
1999
under a previous license agreement. In addition, MTU CFC has agreed to
negotiate a license grant of any separate carbonate fuel cell know-how it
develops during the term of the current Cell License once it is ready for
commercialization. Under our Balance of Plant Cross Licensing and
Cross-Selling Agreement, we may sell to MTU CFC our MW-class modules and
MTU CFC
may sell their sub-MW class modules to us. The Balance of Plant License
continues through July 2008 and may be extended for up to three additional
5-year terms, at the option of either MTU CFC or us.
REVENUE
AND BACKLOG
Our
consolidated revenues for the years ended October 31, 2006, 2005 and 2004
were
$33.3 million, $30.4 million and $31.4 million, respectively. These consolidated
revenues included product sales and revenues of $21.5 million, $17.4 million
and
$12.6 million, respectively, and revenues from research and development
contracts of $11.8 million, $13.0 million and $18.8 million, respectively.
Consolidated revenues for the years ended October 31, 2006, 2005 and 2004
in the
U.S. were $27.5 million, $22.2 million and $23.4 million, respectively, and
consolidated revenues from foreign locations were $5.8 million, $8.2 million
and
$8.0 million, respectively, based on customer order location.
Our
backlog as of October 31, 2006 was approximately $58.0 million compared with
backlog of approximately $42.2 million as of October 31, 2005. Backlog refers
to
the aggregate revenues remaining to be earned at a specified date under
contracts we hold.
· |
Product
order backlog was approximately $18.1 million and $20.3 million as
of
October 31, 2006 and 2005, respectively, representing 8.05 MW as
of
October 31, 2006 and 8.25 MW as of October 31, 2005. Product orders
represent approximately 50 percent of our total funded backlog as
of
October 31, 2006. Backlog for long-term service agreements was
approximately $9.8 million and $6.1 million as of October 31, 2006
and
2005, respectively. Although backlog reflects business that is considered
firm, cancellations or scope adjustments may occur and will be reflected
in our backlog when known.
|
· |
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 approximately $30.1
million
and $15.8 million as of October 31, 2006 and 2005, respectively.
The
unfunded portion of our research and development contracts amounted
to
approximately $21.6 million and $3.9 million as of October 31, 2006
and
2005, 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, 2006 and 2005, we had contracts for power plants totaling 4 MW
under
power purchase agreements ranging from 5 - 10 years. Revenue under these
agreements is recognized as electricity is produced. This revenue is not
included in backlog.
EMPLOYEES
As
of
October 31, 2006 we had 384 full-time employees, of whom 110 were located
at the
Torrington, Connecticut manufacturing plant, and 274 were located at the
Danbury, Connecticut facility or various field offices.
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 Company’s 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. 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.
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 recently 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.
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 (including projected power output)
that are currently not ascertainable. 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 will 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.
Our
Direct FuelCell has been operated 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.
Significant decreases (or short term increases) in the price of these fuels
could also have a material adverse effect on our business because other
generation sources could be more economically attractive to consumers than
our
products.
We
have
contracted with certain customers to provide service of fuel cell power plants
over terms ranging from one to thirteen years. Under the provisions of these
contracts, we provide services to maintain, monitor and repair customer power
plants. Pricing for service contracts is based upon estimates of future costs,
which given the early stage of development could be materially different
from
actual expenses.
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. As we have limited operating experience, warranty costs
are
expensed as incurred. As a result operating results could be negatively impacted
should there be product manufacturing or performance defects.
We
currently face and will continue to face significant
competition.
Our
Direct FuelCell currently faces, 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 proton exchange membrane fuel cells (Ballard
Power Systems, Inc.; United Technologies Corp. or UTC Fuel Cells; and Plug
Power), phosphoric acid fuel cells (UTC Fuel Cells) and solid oxide fuel
cells
(Siemens Westinghouse Electric Company, SOFCo, General Electric, Delphi,
Rolls
Royce 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.
Other
than fuel cell developers, we must also compete with such companies as
Caterpillar, Cummins, 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.
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 large and influential stockholders, which may make it difficult for
a third
party to acquire our common stock.
Our
largest two institutional shareholders each own more than 5%, but less than
10%,
of our outstanding common stock. MTU Friedrichshafen GmbH owns approximately
5%
of our outstanding common stock. James D. Gerson beneficially owns approximately
2% of our outstanding common stock. Loeb Investors Co. LXXV and Warren Bagatelle
(a managing director of an affiliate of Loeb Investors Co. LXXV) collectively
beneficially own approximately 2% of our outstanding common stock. These
ownership levels could make it difficult for a third party to acquire our
common
stock or have input into the decisions made by our board of directors, which
include Michael Bode (Chief Executive Officer of MTU CFC Solutions GmbH),
James
D. Gerson, Warren Bagatelle and Thomas L. Kempner (Chairman and Chief Executive
Officer of an affiliate of Loeb Investors Co. LXXV). MTU CFC is also a licensee
of our technology and a purchaser of our Direct FuelCell products. Therefore,
it
may be in MTU CFC’s interest to possess substantial influence over matters
concerning our overall strategy and technological and commercial
development.
MTU
CFC may develop competing technologies.
MTU
CFC
is currently developing carbonate fuel cell technology. If this technology
does
not use DFC know-how, MTU CFC must use good faith efforts to license the
technology to us. If MTU CFC is successful but does not grant us a license,
it
may be directly competing with us while having a significant ownership interest
in us, and a seat on our board of directors. We have agreed with MTU CFC
to
continue developing products with as much commonality as possible. However,
the
license agreement between us and MTU CFC provides that each of us retains
the
right to independently pursue the development of carbonate fuel cell
technologies.
We
have limited experience manufacturing our Direct FuelCell products on a
commercial basis, which may adversely affect our planned increases in production
capacity and our ability to satisfy customer
requirements.
We
have
limited experience manufacturing our Direct FuelCell products on a commercial
basis. Our manufacturing, testing and conditioning facilities have equipment
in
place for a production capacity of 50 MW per year. We expect that we will
then
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.
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 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 Direct FuelCell
products.
Our
plans
are dependent upon market acceptance of, as well as enhancements to, those
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 Direct FuelCell products
may be affected by many factors that are out of our control,
including:
· |
the
cost competitiveness of our fuel cell products;
|
· |
the
future costs of natural gas and other fuels used by our fuel cell
products;
|
· |
consumer
reluctance to try a new product;
|
· |
perceptions
of the safety of our fuel cell products;
|
· |
the
market for distributed generation;
|
· |
local
permitting and environmental requirements; and
|
· |
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 Direct FuelCell products and may never achieve profitability.
As
we
continue to commercialize our Direct FuelCell products, we will continue
to
develop warranties, 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.
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 (“DOE”), 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.
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 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. Two of our patents that
were the result of DOE-funded research prior to January 1988 (the date that
we
qualified as a “small business”) are owned by the U.S. government and have been
licensed to us. This license is revocable only in the limited circumstances
where it has been demonstrated that we are not making an effort to commercialize
the invention. We own all patents resulting from research funded by our DOE
contracts awarded after January 1988 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.”
Ten
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. 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 a result
of
our acquisition of Global, the number of our employees increased and therefore,
we temporarily did not qualify as a “small business.” Following the sale of
Global and its TEG product line on May 27, 2004, we again qualified as a
“small
business”; however, we cannot assure you that we will continue to qualify as a
“small business” in the future.
Our
future success and growth is dependent on our distribution
strategy.
We
cannot
assure you that we will enter into distributor relationships that are consistent
with, or sufficient to support, our commercialization plans or 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 us 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 effect on our stock price.
To
the extent we enter into distributor relationships, the failure of these
distributors in assisting us with the marketing and distribution of our products
may adversely affect our results of operations and financial
condition.
We
cannot
be sure that MTU CFC will continue to, or original equipment manufacturers
(“OEMs”) will, manufacture or package products using our Direct FuelCell
components. In this area, 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 MTU CFC or other
OEMs
could adversely affect the market for our Direct FuelCell 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 components
for Direct FuelCell products.
We
purchase several key components of our Direct FuelCell products from other
companies and rely on third-party suppliers for the balance-of-plant components
in our Direct FuelCell products. There are a limited number of suppliers
for
some of the key components of Direct FuelCell products. A supplier’s failure to
develop and supply components in a timely manner or to supply components
that
meet our quality, quantity or cost requirements or 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. The patents that we have obtained will expire between 2008 and
2024
and the average remaining life of our U.S. patents is approximately 11.4
years.
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 patentable, 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 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. Accordingly, we cannot assure you that:
· |
any
of the U.S., Canadian or other foreign 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 patentable, 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 has 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 material 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. 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.
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 the budgeting,
forecasting and other process control 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 federal, state, provincial or local regulation with respect to,
among
other things, emissions and siting. Assuming no co-generation applications
are
used in conjunction with our Direct FuelCell plants, they will discharge
humid
flue gas at temperatures of up to 800o
F, water
at temperatures of approximately 10-20
o
F above
surrounding air temperatures and carbon dioxide.
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 Direct FuelCell 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.
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.
We
may be required to conduct environmental remediation activities, which could
be
expensive.
We
are
subject to a number of environmental laws and regulations, including those
concerning the handling, treatment, storage and disposal of hazardous materials.
These environmental laws generally impose liability on present and former
owners
and operators, transporters and generators for remediation of contaminated
properties. We believe that our businesses are operating in compliance in
all
material respects with applicable environmental laws, many of which provide
for
substantial penalties for violations. We cannot assure you that future changes
in such laws, interpretations of existing regulations or the discovery of
currently unknown problems or conditions will not require substantial additional
expenditures. Any noncompliance with these laws and regulations could subject
us
to material administrative, civil or criminal penalties or other liabilities.
In
addition, we may be required to incur substantial costs to comply with current
or future environmental and safety laws and regulations.
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 our
Direct FuelCell products use corrosive carbonate material, which could expose
us
to potential liability claims. Although we have comprehensive safety,
maintenance and training programs in place, 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
Direct FuelCell 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 our insurance coverage on acceptable
terms.
We
are subject to risks inherent in international
operations.
Since
we
market our Direct FuelCell products both inside and outside the U.S. and
Canada,
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. 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, 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 operations and
revenues.
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:
· |
failure
to meet our product development and commercialization
milestones;
|
· |
variations
in our quarterly operating results from the expectations of securities
analysts or investors;
|
· |
downward
revisions in securities analysts’ estimates or changes in general market
conditions;
|
· |
announcements
of technological innovations or new products or services by us or
our
competitors;
|
· |
announcements
by us or our competitors of significant acquisitions, strategic
partnerships, joint ventures or capital
commitments;
|
· |
additions
or departures of key personnel;
|
· |
investor
perception of our industry or our prospects;
|
· |
insider
selling or buying;
|
· |
demand
for our common stock; and
|
· |
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 management’s 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.
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 shares could
negatively impact our company.
The
terms
of the Series 1 preferred shares issued by FuelCell Energy, Ltd., our
wholly-owned, indirect subsidiary, provide rights to the holder, Enbridge
Inc.
(“Enbridge”), including dividend and conversion rights among others that could
negatively impact us. For example, the terms of the Series 1 preferred shares
provide that the holders are entitled to receive cumulative dividends for
each
calendar quarter for so long as such shares are outstanding. Assuming the
exchange rate for Canadian dollars is Cdn.$1.1758 to U.S.$1.00 (exchange
rate on
January 10, 2007) at the time of the applicable dividend payment date, we
are
required to pay a preferred dividend of approximately $265,776 per calendar
quarter, subject to reduction in accordance with the terms of the Series
1
preferred shares. The terms of the Series 1 preferred shares also require
that
the holder be paid any accrued and unpaid dividends on December 31, 2010.
To the
extent that there is a significant amount of accrued dividends that is unpaid
as
of December 31, 2010 and we do not have sufficient working capital at that
time
to pay the accrued dividends, our financial condition could be adversely
affected. We have guaranteed these dividend obligations, including paying
a
minimum of Cdn.$500,000 in cash annually to Enbridge for so long as Enbridge
holds the Series 1 preferred shares. We have also guaranteed the liquidation
obligations of FuelCell Energy, Ltd. under the Series 1 preferred shares.
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 U.S.$6.22 (our common stock closing
price on January 10, 2007) and the exchange rate for Canadian dollars is
Cdn.$1.1758 to U.S.$1.00 (exchange rate on January 10, 2007) at the time
of
conversion, we would be required to issue approximately 3,598,260 shares
of our
common stock.
The
terms
of the Series B Preferred Shares also provide rights to their holders that
could
negatively impact us. Holders of the Series B Preferred Shares 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.
Item
2. PROPERTIES
Our
headquarters are located in Danbury, Connecticut. The following is a summary
of
our offices and locations:
Location
|
|
Business
Use
|
|
Square
Footage
|
|
Lease
Expiration Dates
|
Danbury,
Connecticut
|
|
Corporation
Headquarters, Research and Development, Sales, Marketing, Purchasing
and
Administration
|
|
72,000
|
|
Company
owned
|
|
|
|
|
|
|
|
Torrington,
Connecticut
|
|
Manufacturing
|
|
65,000
|
|
December
2010 (1)
|
|
|
|
|
|
|
|
Danbury,
Connecticut
|
|
Manufacturing
and Operations
|
|
38,000
|
|
October
2009
|
|
|
|
|
|
|
|
(1)
We
have
an option to extend the lease for an additional five years.
Item
3. LEGAL PROCEEDINGS
On
November 14, 2005, Zoot Properties, LLC and Zoot Enterprises, Inc. (“Zoot”)
commenced an action in the U.S. District Court for the District of Montana,
Butte Division against the Company and one of its distribution partners,
PPL
Energy Services Holding, LLC. The lawsuit alleges that the plaintiffs purchased
fuel cells from PPL that were manufactured by the Company, and that these
fuel
cells have failed to perform as represented and warranted. Zoot is seeking
rescission of the contract with PPL, totaling approximately $2.5 million.
Zoot
may also be seeking damages for breach of contract and under tort arising
out of
the alleged misrepresentation. The Company intends to vigorously defend the
action. The Company is unable to predict at this time the ultimate outcome
of
this lawsuit and therefore no loss contingency has been included in the
consolidated financial statements.
Item
4. SUBMISSION OF MATTERS TO A VOTE OF SECURITY HOLDERS
None
PART
II
Item
5. MARKET FOR REGISTRANT’S COMMON EQUITY AND RELATED STOCKHOLDER
MATTERS
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 has traded under the symbol “FCEL” on the Nasdaq Stock Market since
June 7, 2000. 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
Stock Market during the indicated quarters.
|
|
Common
Stock
Price
|
|
|
|
High
|
|
Low
|
|
Year
Ended October 31, 2004
|
|
|
|
|
|
|
|
First
Quarter
|
|
$
|
17.79
|
|
$
|
10.75
|
|
Second
Quarter
|
|
$
|
20.30
|
|
$
|
11.54
|
|
Third
Quarter
|
|
$
|
17.59
|
|
$
|
8.30
|
|
Fourth
Quarter
|
|
$
|
13.36
|
|
$
|
7.16
|
|
|
|
|
|
|
|
|
|
Year
Ended October 31, 2005
|
|
|
|
|
|
|
|
First
Quarter
|
|
$
|
13.45
|
|
$
|
7.98
|
|
Second
Quarter
|
|
$
|
12.06
|
|
$
|
7.71
|
|
Third
Quarter
|
|
$
|
10.94
|
|
$
|
7.05
|
|
Fourth
Quarter
|
|
$
|
12.25
|
|
$
|
8.25
|
|
|
|
|
|
|
|
|
|
Year
Ended October 31, 2006
|
|
|
|
|
|
|
|
First
Quarter
|
|
$
|
10.90
|
|
$
|
7.90
|
|
Second
Quarter
|
|
$
|
15.00
|
|
$
|
9.22
|
|
Third
Quarter
|
|
$
|
13.97
|
|
$
|
8.29
|
|
Fourth
Quarter
|
|
$
|
9.90
|
|
$
|
6.59
|
|
On
January 10, 2007, the closing price of our common stock on the Nasdaq Stock
Market was $6.22 per share. As of January 10, 2007, there were 736 holders
of
record of our common stock.
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.
SERIES
1 PREFERRED SHARES
On
August
4, 2003, we entered into a combination agreement with Global
Thermoelectric Inc. (“Global”) to combine Global with us in a share-for-share
exchange pursuant to a Plan of Arrangement subject to approval by the Court
of
Queen’s Bench of Alberta, Canada. On October 31, 2003, our shareholders and the
shareholders of Global approved the combination. On October 31, 2003, the
Court
of Queen’s Bench of Alberta issued an order approving the combination. On
November 3, 2003, the combination transaction was consummated. In the aggregate,
we issued approximately 8.2 million shares of our common stock and exchangeable
shares in the acquisition. Following our acquisition of Global, Global’s Series
2 preferred shares remained outstanding in Global. At the time of the sale
of
our thermoelectric generator business, the holder of the Series 2 preferred
shares exchanged them for Series 1 Class A cumulative redeemable exchangeable
preferred shares (which were referred to as the Series 1 preferred shares)
issued by FuelCell Energy, Ltd., one of our indirect, wholly-owned subsidiaries.
We have guaranteed the obligations of FuelCell Energy, Ltd. under the Series
1
preferred shares.
The
Series 1 preferred shares may be converted into shares of our common stock
at
the following conversion prices:
· |
Cdn.$120.22
per share of our common stock until July 31,
2010;
|
· |
Cdn.$129.46
per share of our common stock after July 31, 2010 until July 31,
2015;
|
· |
Cdn.$138.71
per share of our common stock after July 31, 2015 until July 31,
2020;
and
|
· |
at
any time after July 31, 2020, the price equal to 95% of the then
current
market price (converted to Cdn.$ at the time of such calculation)
of
shares of our common stock at the time of
conversion.
|
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 (which is the amount currently
outstanding) and assume that all accrued dividends on the Series 1 preferred
shares 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.$1.1758 to U.S.$1.00 (exchange rate on January 10, 2007) at
the
time of the conversion:
· |
if
the Series 1 preferred shares convert prior to July 31, 2010, we
would be
required to issue approximately 207,952 shares of our common
stock;
|
· |
if
the Series 1 preferred shares convert after July 31, 2010, but prior
to
July 31, 2015, we would be required to issue approximately 193,110
shares
of our common stock;
|
· |
if
the Series 1 preferred shares convert after July 31, 2015, but prior
to
July 31, 2020, we would be required to issue approximately 180,232
shares
of our common stock; and
|
· |
if
the Series 1 preferred shares convert any time after July 31, 2020,
assuming
our common stock price is U.S. $6.22 (our common stock closing price
on
January 10, 2007) at the time of conversion, we would be required
to issue
approximately 3,598,260 shares of our common stock.
|
Subject
to the Business Corporations Act (Alberta), the holder of the Series 1 preferred
shares is not entitled to receive notice of or to attend or vote at any meeting
of the FuelCell Energy, Ltd. Common shareholders. At present, we own all
of the
FuelCell Energy, Ltd. 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
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
current holder of the Series 1 preferred shares, as long as Enbridge holds
the
shares. Interest accrues on cumulative unpaid dividends at a 2.45% quarterly
rate, compounded quarterly, until payment thereof. All cumulative unpaid
dividends must be paid by December 31, 2010. Subsequent to 2010, FuelCell
Energy, Ltd. would be required to pay annual dividend amounts totaling Cdn.$1.25
million so long as the Series 1 Preferred shares remain outstanding. Cumulative
unpaid dividends of $5.3
million on the Series 1 preferred shares were outstanding as of October 31,
2006. We have guaranteed the dividend obligations of FuelCell Energy, Ltd.
to
the Series 1 preferred shareholders.
Subject
to the Business Corporations Act (Alberta), we may redeem the Series 1 preferred
shares, in whole or part, at any time, if on the day that the notice of
redemption is first given, the volume-weighted average price at which our
common
stock is traded on the applicable stock exchange during the 20 consecutive
trading days ending on a date not earlier than the fifth preceding day on
which
the notice of redemption is given was not less than a 20% premium to the
current
conversion price on payment of Cdn.$25.00 per Series 1 Preferred Share to
be
redeemed, together with an amount equal to all accrued and unpaid dividends
to
the date fixed for redemption. On or after July 31, 2010, the Series 1 preferred
shares are redeemable by us at any time on payment of Cdn.$25.00 per Series
1
preferred share to be redeemed together with an amount equal to all accrued
and
unpaid dividends to the date fixed for redemption. Holders of the Series
1
preferred shares do not have any mandatory or conditional redemption rights.
There are currently 1,000,000 Series 1 preferred shares
outstanding.
In
the
event of the liquidation, dissolution or winding up of FuelCell Energy, Ltd.,
whether voluntary or involuntary, or any other distribution of its assets
among
its shareholders for the purpose of winding up its affairs, the holder of
the
Series 1 preferred shares will be entitled to receive the amount paid on
such
Series 1 preferred shares (currently Cdn.$25.0 million) together with an
amount
equal to all accrued and unpaid dividends thereon, before any amount will
be
paid or any of FuelCell Energy, Ltd.’s property or assets will be distributed to
the holders of FuelCell Energy, Ltd.’s common stock. After payment to the holder
of the Series 1 preferred shares of the amounts payable to them, the holder
of
the Series 1 preferred shares will not be entitled to share in any other
distribution of FuelCell Energy, Ltd.’s property or assets. We have guaranteed
the liquidation obligations of FuelCell Energy, Ltd. under the Series 1
preferred shares.
SERIES
B PREFERRED SHARES
On
November 11, 2004, we entered into a purchase agreement with Citigroup Global
Markets Inc., RBC Capital Markets Corporation, Adams Harkness, Inc., and
Lazard
Freres & Co., LLC (the “Initial Purchasers”) for the private placement under
Rule 144A of up to 135,000 shares of our 5% Series B Cumulative Convertible
Perpetual Preferred Stock (Liquidation Preference $1,000) (“Series B Preferred
Stock”). On November 17, 2004 and January 25, 2005, we closed on the sale of
100,000 shares and 5,875 shares, respectively, of Series B Preferred Stock
to
the Initial Purchasers.
At
October 31, 2006 and 2005, there were 200,000 authorized of which 64,120
and
105,875 shares were issued and outstanding, respectively. The carrying value
of
the Series B Preferred Stock as of October 31, 2006 and 2005 represents the
net
proceeds to us of approximately $60.0 million and $99.0 million, respectively.
During fiscal 2006, we converted 41,755 shares of Series B Preferred Stock
(the
"Shares") into 3,553,615 shares of our common stock. The conversion occurred
pursuant to the terms of the Certificate of Designation for the Series B
Preferred Stock, whereby upon conversion, the holders received 85.1064 shares
of
our common stock per share of Series B Preferred Stock. In addition, pursuant
to
this conversion, we paid a conversion premium of $4.3 million.
The
following is a summary of certain provisions of our Series B Preferred Stock.
The resale of the shares of our Series B Preferred Stock and the resale of
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.
Ranking
Shares
of
our 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 will be paid on the basis of a 360-day year consisting
of twelve 30-day months. Dividends on the shares of our Series B Preferred
Stock
will accumulate and be cumulative from the date of original issuance.
Accumulated dividends on the shares of our Series B preferred stock will
not
bear any interest.
The
dividend rate on the Series B Preferred Stock is subject to upward adjustment
as
set forth in the certificate of designation of the Series B Preferred Stock
if
we fail to pay, or to set apart funds to pay, dividends on the shares of
our
Series B Preferred Stock for any quarterly dividend period. The dividend
rate on
the Series B Preferred Stock 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 Shares (or the underlying common shares) set forth in the registration
rights agreement.
No
dividends or other distributions may be paid or set apart for payment upon
our
common shares (other than a dividend payable solely in shares of a like or
junior ranking) unless all accumulated and unpaid dividends have been paid
or
funds or shares of common stock therefore have been set apart on our Series
B
Preferred Stock.
We
may
pay dividends on the Series B Preferred Stock:
· |
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.
|
Liquidation
The
Series B Preferred Stock has a liquidation preference of $1,000 per share.
Upon
any voluntary or involuntary liquidation, dissolution or winding up of our
company resulting in a distribution of assets to the holders of any class
or
series of our capital stock, each holder of shares of our Series B preferred
stock will be entitled to payment out of our assets available for distribution
of an amount equal to the liquidation preference per share of Series B Preferred
Stock held by that holder, plus all accumulated and unpaid dividends on those
shares to the date of that liquidation, dissolution, or winding up, before
any
distribution is made on any junior shares, including shares of our common
stock,
but after any distributions on any of our indebtedness or senior shares (if
any). After payment in full of the liquidation preference and all accumulated
and unpaid dividends to which holders of shares of our Series B preferred
stock
are entitled, holders of shares of our Series B preferred stock will not
be
entitled to any further participation in any distribution of our assets.
Conversion
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. 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. Upon conversion, holders of Series B preferred stock will
not
receive a cash payment for any accumulated dividends. Instead accumulated
dividends, if any, will be cancelled.
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% of the then prevailing conversion price for 20 trading days
during
any consecutive 30 trading day period, as described in the certificate of
designation for the Series B preferred stock.
If
holders of shares of our 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 discussed below
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 of the Series B Preferred Stock is to
prevent
dilution of the interests of the holders of the Series B Preferred Shares,
including on account of 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.
|
Shares
of
our Series B Preferred Stock will not be redeemable by us, except in the
case of
a fundamental change (as described below and in the certificate of designation)
whereby holders may require us to purchase all or part of their shares at
a
redemption price equal to 100% of the liquidation preference of the shares
of
Series B Preferred Stock to be repurchased, plus accrued and unpaid dividends,
if any. 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% 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.
Redemption
by holders of the Series B Preferred Stock can only occur upon a fundamental
change, which the Company does not consider to be probable at this time.
Accordingly, future adjustments of the redemption price will only be made
if and
when a fundamental change is considered probable.
A
“fundamental change” will be deemed to have occurred if any of the following
occurs:
(1)
any
"person" or "group" is or becomes the beneficial owner, directly or indirectly,
of 50% 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;
(2)
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;
(3)
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
(4)
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% 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.
Notwithstanding
the foregoing, holders of shares of Series B Preferred Stock will not have
the
right to require us to repurchase their shares if either:
· |
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% of the conversion price of the shares of Series B Preferred
Stock immediately before the fundamental change or
announcement;
|
· |
at
least 90% of the consideration, excluding cash payments for fractional
shares and in respect of dissenters' appraisal rights, in 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 number 4 above of a fundamental change event, the transaction
is effected solely to change our jurisdiction of
incorporation.
|
Voting
Holders
of shares of our Series B Preferred Stock have no voting rights unless (1)
dividends on any shares of our Series B Preferred Stock or any other class
or
series of stock ranking on a parity with the shares of our Series B Preferred
Stock with respect to the payment of dividends shall be in arrears for dividend
periods, whether or not consecutive, containing in the aggregate a number
of
days equivalent to six calendar quarters or (2) we fail to pay the repurchase
price, plus accrued and unpaid dividends, if any, on the fundamental change
repurchase date for shares of our Series B Preferred Stock following a
fundamental change (as described in the certificate of designation for the
Series B Preferred Stock). In each such case, the holders of shares of our
Series B Preferred Stock (voting separately as a class with all other series
of
other Preferred Stock on parity with our Series B Preferred Stock upon which
like voting rights have been conferred and are exercisable, if any) will
be
entitled to vote for the election of two directors in addition to those
directors on the board of directors at such time at the next annual meeting
of
shareholders and each subsequent meeting until the repurchase price or all
dividends accumulated on the shares of our Series B Preferred Stock have
been
fully paid or set aside for payment. The term of office of all directors
elected
by the holders of shares of our Series B Preferred Stock will terminate
immediately upon the termination of the right of holders of shares of our
Series
B Preferred Stock to vote for directors.
So
long
as any shares of our Series B Preferred Stock remain outstanding, we will
not,
without the consent of the holders of at least two-thirds of the shares of
our
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 our 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 our 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 our Series B Preferred Stock or the holders thereof
without the affirmative vote of not less than two-thirds of the issued and
outstanding shares of our Series B Preferred Stock.
UNREGISTERED
SECURITIES
The
following unregistered securities were issued during the period of November
1,
2004 through January 11, 2007:
Shares
Issued
As
discussed above, on November 17, 2004 and January 25, 2005, we sold 100,000
shares and 5,875 shares, respectively, of Series B Preferred Stock, which
were
not registered upon issuance to the initial purchasers. During fiscal 2006,
we
converted 41,755 shares of Series B Preferred Stock (the "Shares") into
3,553,615 shares of our common stock and at October 31, 2006, there were
64,120
shares of Series B Preferred Stock outstanding.
Warrants
Issued
On
April
6, 2004, we issued warrants to purchase 1,000,000 shares of our common stock
to
Marubeni Corporation (Marubeni) in conjunction with a revised distribution
agreement. Pursuant to the terms of this agreement, Marubeni placed orders
for 4
megawatts of DFC power plants, and committed to creating a sub-distributor
network and to provide additional support for our products. All previously
issued warrants to Marubeni were cancelled. As part of these warrant agreements,
the warrants vest in separate tranches once Marubeni has ordered totals of
between 5 MW and 45 MW of our products. As of October 31, 2006, 800,000 of
these
warrants had expired. The exercise price of the remaining 200,000 warrants
(which are not vested) is $18.73 per share and the warrants will expire April
2007, if not earned and exercised sooner.
On
July
7, 2005, we issued warrants to purchase up to an aggregate of 1,000,000 shares
of our common stock to Enbridge Inc. (Enbridge) in conjunction with an amended
distribution agreement. All previously issued warrants to Enbridge were
cancelled. The warrants vest on a graduated scale based on the total number
of
megawatts contained in product orders and the timing of when such orders
are
generated by Enbridge. In October 2006, Enbridge placed a qualifying order
resulting in vesting of 30,000 warrants with an exercise price of $9.89.
The
expiration date of these vested warrants is October 31, 2008. The exercise
prices of the remaining 970,000 warrants not vested range from $9.89 to $11.87
per share and the expiration dates range from June 30, 2008 to June 30, 2010,
if
not earned and exercised sooner.
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, 2006 have been derived
from
our audited consolidated financial statements together with the notes thereto
included elsewhere in this Report (the “Financial Statements”). The data set
forth below is qualified by reference to, and should be read in conjunction
with, the Financial Statements and “Management’s Discussion and Analysis of
Financial Condition and Results of Operations” included elsewhere in this
Report.
(Amounts
presented in thousands, except for per share amounts)
Consolidated
Statement of Operations Data:
|
|
Year
Ended October 31,
|
|
|
|
2006
|
|
2005
|
|
2004
|
|
2003
|
|
2002
|
|
Revenues:
|
|
|
|
|
|
|
|
|
|
|
|
Product
sales and revenue
|
|
$
|
21,514
|
|
$
|
17,398
|
|
$
|
12,636
|
|
$
|
16,081
|
|
$
|
7,656
|
|
Research
and development contracts
|
|
|
11,774
|
|
|
12,972
|
|
|
18,750
|
|
|
17,709
|
|
|
33,575
|
|
Total
revenues
|
|
|
33,288
|
|
|
30,370
|
|
|
31,386
|
|
|
33,790
|
|
|
41,231
|
|
Costs
and expenses:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cost
of product sales and revenues
|
|
|
61,526
|
|
|
52,067
|
|
|
39,961
|
|
|
50,391
|
|
|
32,129
|
|
Cost
of research and development contracts
|
|
|
10,330
|
|
|
13,183
|
|
|
27,290
|
|
|
35,827
|
|
|
45,664
|
|
Administrative
and selling expenses
|
|
|
17,759
|
|
|
14,154
|
|
|
14,901
|
|
|
12,631
|
|
|
10,451
|
|
Research
and development expenses
|
|
|
24,714
|
|
|
21,840
|
|
|
26,677
|
|
|
8,509
|
|
|
6,806
|
|
Purchased
in-process research and development
|
|
|
—
|
|
|
—
|
|
|
12,200
|
|
|
—
|
|
|
—
|
|
Total
costs and expenses
|
|
|
114,329
|
|
|
101,244
|
|
|
121,029
|
|
|
107,358
|
|
|
95,050
|
|
Loss
from operations
|
|
|
(81,041
|
)
|
|
(70,874
|
)
|
|
(89,643
|
)
|
|
(73,568
|
)
|
|
(53,819
|
)
|
License
fee income, net
|
|
|
42
|
|
|
70
|
|
|
19
|
|
|
270
|
|
|
270
|
|
Interest
expense
|
|
|
(103
|
)
|
|
(103
|
)
|
|
(137
|
)
|
|
(128
|
)
|
|
(160
|
)
|
Loss
from equity investments
|
|
|
(828
|
)
|
|
(1,553
|
)
|
|
—
|
|
|
—
|
|
|
—
|
|
Loss
on derivatives
|
|
|
(233
|
)
|
|
—
|
|
|
—
|
|
|
—
|
|
|
—
|
|
Interest
and other income, net
|
|
|
5,951
|
|
|
5,526
|
|
|
2,472
|
|
|
6,012
|
|
|
4,876
|
|
Redeemable
minority interest
|
|
|
107
|
|
|
—
|
|
|
—
|
|
|
—
|
|
|
—
|
|
Provision
for taxes
|
|
|
—
|
|
|
—
|
|
|
—
|
|
|
—
|
|
|
(7
|
)
|
Loss
from continuing operations
|
|
|
(76,105
|
)
|
|
(66,934
|
)
|
|
(87,289
|
)
|
|
(67,414
|
)
|
|
(48,840
|
)
|
Discontinued
operations, net of tax
|
|
|
—
|
|
|
(1,252
|
)
|
|
846
|
|
|
—
|
|
|
—
|
|
Net
loss
|
|
|
(76,105
|
)
|
|
(68,186
|
)
|
|
(86,443
|
)
|
|
(67,414
|
)
|
|
(48,840
|
)
|
Preferred
stock dividends
|
|
|
(8,117
|
)
|
|
(6,077
|
)
|
|
(964
|
)
|
|
—
|
|
|
—
|
|
Net
loss to common shareholders
|
|
$
|
(84,222
|
)
|
$
|
(74,263
|
)
|
$
|
(87,407
|
)
|
$
|
(67,414
|
)
|
$
|
(48,840
|
)
|
Basic
and diluted loss per share:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Continuing
operations
|
|
$
|
(1.65
|
)
|
$
|
(1.51
|
)
|
$
|
(1.84
|
)
|
$
|
(1.71
|
)
|
$
|
(1.25
|
)
|
Discontinued
operations
|
|
|
—
|
|
|
(.03
|
)
|
|
0.01
|
|
|
—
|
|
|
—
|
|
Net
loss to common shareholders
|
|
$
|
(1.65
|
)
|
$
|
(1.54
|
)
|
$
|
(1.83
|
)
|
$
|
(1.71
|
)
|
$
|
(1.25
|
)
|
Basic
and diluted weighted average shares
Outstanding
|
|
|
51,047
|
|
|
48,261
|
|
|
47,875
|
|
|
39,342
|
|
|
39,135
|
|
Consolidated
Balance Sheet Data:
|
|
|
|
|
|
2006
|
|
2005
|
|
2004
|
|
2003
|
|
2002
|
|
Cash,
cash equivalents and short term investments (U.S. treasury
securities)
|
|
$
|
107,533
|
|
$
|
136,032
|
|
$
|
152,395
|
|
$
|
134,750
|
|
$
|
205,996
|
|
Working
capital
|
|
|
105,868
|
|
|
140,736
|
|
|
156,798
|
|
|
143,998
|
|
|
218,423
|
|
Total
current assets
|
|
|
133,709
|
|
|
161,894
|
|
|
178,866
|
|
|
160,792
|
|
|
234,739
|
|
Long-term
investments (U.S. treasury securities)
|
|
|
13,054
|
|
|
43,928
|
|
|
—
|
|
|
18,690
|
|
|
14,542
|
|
Total
assets
|
|
|
206,652
|
|
|
265,520
|
|
|
236,510
|
|
|
223,363
|
|
|
289,803
|
|
Total
current liabilities
|
|
|
27,841
|
|
|
21,158
|
|
|
22,070
|
|
|
16,794
|
|
|
16,316
|
|
Total
non-current liabilities
|
|
|
7,401
|
|
|
2,892
|
|
|
1,476
|
|
|
1,484
|
|
|
1,785
|
|
Redeemable
minority interest
|
|
|
10,665
|
|
|
11,517
|
|
|
10,259
|
|
|
—
|
|
|
—
|
|
Redeemable
preferred stock
|
|
|
59,950
|
|
|
98,989
|
|
|
—
|
|
|
—
|
|
|
—
|
|
Total
shareholders’ equity
|
|
|
100,795
|
|
|
130,964
|
|
|
202,705
|
|
|
205,085
|
|
|
271,702
|
|
Book
value per share(1)
|
|
$
|
1.90
|
|
$
|
2.70
|
|
$
|
4.21
|
|
$
|
5.20
|
|
$
|
6.93
|
|
(1) Calculated
as total shareholders’ equity divided by common shares issued and outstanding as
of the balance sheet date.
Item
7. MANAGEMENT’S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND RESULTS OF
OPERATIONS
Management’s
Discussion and Analysis of Financial Condition and Results of Operations
(“MD&A”) is provided as a supplement to the accompanying financial
statements and footnotes to help provide an understanding of our financial
condition, changes in our financial condition and results of operations. The
MD&A is organized as follows:
Caution
concerning forward-looking statements. This
section discusses how certain forward-looking statements made by us throughout
the MD&A are based on management’s present expectations about future events
and are inherently susceptible to uncertainty and changes in
circumstances.
Overview
and recent developments.
This
section provides a general description of our business. We also briefly
summarize any significant events occurring subsequent to the close of the
reporting period.
Critical
accounting policies and estimates.
This
section discusses those accounting policies and estimates that are both
considered important to our financial condition and operating results and
require significant judgment and estimates on the part of management in their
application.
Results
of operations.
This
section provides an analysis of our results of operations for the years ended
October 31, 2006, 2005 and 2004. In addition, a description is provided of
transactions and events that impact the comparability of the results being
analyzed.
Liquidity
and capital resources.
This
section provides an analysis of our cash position and cash flows.
Recent
accounting pronouncements.
This
section summarizes recent accounting pronouncements and their impact on the
Company.
Factors
that may affect future results. In
this section, we detail risk factors that affect our quarterly and annual
results, but which are difficult to predict.
CAUTION
CONCERNING FORWARD-LOOKING STATEMENTS
The
following discussion should be read in conjunction with the accompanying
Consolidated Financial Statements and Notes thereto included within this report.
In addition to historical information, this Form 10-K and the following
discussion contain 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, general risks associated with product development,
manufacturing, changes in the utility regulatory environment, potential
volatility of energy prices, rapid technological change, ability to reach
product cost objectives, and competition, as well as other risks set forth
in
our filings with the Securities and Exchange Commission including those set
forth under the caption “Risk Factors” in this report.
OVERVIEW
AND RECENT DEVELOPMENTS
Overview
FuelCell
Energy, Inc. (the “Company”, “we”, “us” or “our”) is a world leader in the
development and manufacture of fuel cell power plants for ultra-clean, efficient
and reliable electric power generation. Our products are designed to meet
the 24/7 baseload power needs of commercial, industrial, government and
utility customers. To date our products have generated over 150 million kilowatt
hours of electricity and we have units operating at over 50 locations around
the
world.
We
have
been developing fuel cell technology since our founding in 1969. Our core
carbonate fuel cell products (“Direct FuelCell®
or
DFC®
Power
Plants”), offer stationary applications for customers. In addition to our
current commercial products, we continue to develop our next generation of
carbonate fuel cell and hybrid products as well as planar solid oxide fuel
cell
(“SOFC”) technology with our own and government research and development funds.
Our
proprietary carbonate DFC power plants electrochemically (meaning without
combustion) produce electricity directly from readily available hydrocarbon
fuels, such as natural gas and biomass fuels. Customers buy fuel cells to
improve reliability and reduce cost and emissions.
We
believe our products offer significant advantages compared to other power
generation technologies:
· |
Reliable
24/7 baseload power,
|
· |
Ultra-clean
(e.g. virtually zero emissions) quiet
operation,
|
· |
Lower
cost to generate electricity, and
|
· |
The
ability to site units locally and provide high temperature heat for
cogeneration applications.
|
Typical
customers for our products include manufacturers, mission critical institutions
such as correction facilities and government installations, hotels and customers
who can use waste or byproducts of their operatons for fuel such as breweries,
food processors and waste water treatment facilities.
With
increasing demand for renewable and ultraclean power options, and increased
volatility and uncertainty in electric markets, our customers gain control
of
power generation economics, reliability and emissions.
Our fuel
cells offer flexible siting and easy permitting.
Through
December 31, 2006, our cumulative fleet availability was greater than 90
percent. Our DFC power plants are protected by 46 U.S. and 74 international
patents and we have also submitted 38 U.S. and 123 international patent
applications.
Our
business strategy is to expand our leadership position in key markets, build
multi-megawatt markets and continue to reduce the costs of our products. We
believe that with the emergence of the RPS markets, the growth of the California
market and continuing product cost reduction, we are well positioned to move
to
profitability. At a sustained annual order and production volume of
approximately 35 MW to 50 MW, depending on product mix, geographic location
and
other variables such as fuel prices, we can reach gross margin breakeven. Our
net income break-even can be achieved at a sustained annual order and volume
production of approximately 75-100 MW assuming a mix of sub-MW and MW sales.
Our
2.4 MW product currently has a production cost at market clearing prices in
certain regions such as Connecticut. Thus, if product mix trends more toward
MW
and multi-MW orders, then we believe that company profitability can achieved
at
annual volumes lower than 75 MW.
Recent
Developments
Change
in Executive Management
On
January 12, 2006, FuelCell Energy, Inc. announced that R. Daniel Brdar was
promoted to President and Chief Executive Officer. Effective January 12,
2007, R. Daniel Brdar was appointed Chairman of the Board. Jerry D. Leitman
resigned as Chairman of the Board and as a member of the Company's
Board.
On
February 15, 2006, Dr. Hans Maru retired as Chief Technology Officer, but will
remain as a consultant to the Company. The Chief Technology Officer
responsibilities have been assumed by executives within the
Company.
On
April
17, 2006, Bruce Ludemann was named Senior
Vice President of Sales and Marketing for the Company and has been focusing
on
MW and multi-MW sales opportunities and developing repeatable customers in
the
Company’s key global markets.
Conversion
of Series B Cumulative Convertible Preferred Stock
We
have
completed transactions with certain holders of the Company’s Series B Cumulative
Convertible Preferred Stock to convert an aggregate of 41,755 shares of Series
B
Preferred Stock into approximately 3.6 million shares of common stock. Pursuant
to the conversion of the preferred shares, we have paid the holders a per share
conversion premium of approximately $4.3 million or an average of $103.02 per
share of Series B Preferred Stock. This conversion resulted in a charge to
preferred stock dividends on the consolidated statement of operations of $4.3
million or $0.08 per basic and diluted share for the fiscal year ended October
31, 2006. As a result of this conversion, quarterly dividend obligations have
been reduced by approximately $0.5 million or $0.01 per basic and diluted share,
which began in the third quarter of fiscal 2006.
Common
Stock Offering
During
fiscal 2006, we sold 681,000 shares of our common stock on the open market
pursuant to a S-3 registration statement filed in June 2005. Total net proceeds
to us from the sale of these securities was approximately $8.0 million and
was
used to pay the $4.3 million conversion premium on the converted shares of
our
Series B Preferred Stock and to make dividend payments on our Series B Preferred
Stock.
2006
Equity Incentive Plan
In
February 2006, the Board adopted the Company's 2006 Equity Incentive Plan (the
"2006 Plan"). This plan was approved by shareholders at the Company’s March 2006
Annual Meeting. The purpose of the 2006 Plan is to attract and retain key
employees, directors, advisors and consultants to provide an incentive for
them
to assist the Company to achieve long-range performance goals and to enable
them
to participate in the long-term growth of the Company. There are a total of
2,500,000 shares of Common Stock available for issuance under the 2006 Plan,
subject to adjustment for any stock dividend, recapitalization, stock split,
stock combination or certain other corporate reorganizations.
Adoption
of Statement of Financial Accounting Standard No. 123R, “Share-Based
Payments”
On
November 1, 2005, we adopted Statement of Financial Accounting Standard No.
123R, “Share-Based Payments” (SFAS 123R), which revised SFAS No. 123,
“Accounting for Stock-Based Compensation”. This statement supercedes APB Opinion
No. 25, “Accounting for Stock Issued to Employees.” The revised statement
addresses the accounting for share-based payment transactions with employees
and
other third parties, eliminates the ability to account for share-based
compensation transactions using APB 25 and requires that the compensation costs
relating to such transactions be recognized in the consolidated statement of
operations. Share-based compensation of $4.4 million was recognized in the
consolidated statement of operations for the fiscal year ended October 31,
2006.
Refer to Note 14 of the consolidated financial statements for additional
information.
Change
in Accounting for Series 1 Preferred Shares and Derivative
Liability
In
the
fourth quarter of 2006, the Company recorded
a cumulative net charge of $0.1 million to the consolidated statement of
operations to correct an accounting error related to the Series 1 Preferred
shares of FuelCell Energy, Ltd (a wholly-owned subsidiary of the Company).
This
net charge was recorded in the consolidated statement of operations as a loss
on
derivatives of $0.2 million and a gain related to redeemable minority interest
of $0.1 million. Prior to this change in accounting, the Series 1 Preferred
shares were reported in shareholders’ equity as Preferred shares of subsidiary.
We have concluded that these shares should be accounted for as a redeemable
minority interest in FuelCell Energy, Ltd. As a result, we have reclassified
the
Preferred shares of subsidiary totaling $10.7 million and $11.5 million as
of
October 31, 2006 and 2005, respectively to Redeemable minority interest on
the
consolidated balance sheets. Additionally, in the consolidated balance sheet
as
of October 31, 2005, we have reclassified to accumulated deficit the accretion
of the fair value discount on the Series 1 Preferred shares and dividends paid
on these shares, which had previously been reported in additional
paid-in-capital. No revisions have been made to the historical consolidated
statements of operations.
As
part
of this accounting change, we determined that the Series 1 Preferred shares
include embedded derivatives (the conversion feature of the security and its
variable dividend obligation) which require bifurcation from the host contract
and separate accounting in accordance with SFAS 133, Accounting
for Derivative Instruments and Hedging Activities.
This
derivative liability is classified as a component of Long-term debt and other
liabilities on the Consolidated Balance Sheets. Refer to Note 12 of Notes to
Consolidated Financial Statements for additional information.
Reclassification
of Series B Cumulative Convertible Perpetual Preferred Stock
EITF
Topic D-98, “Classification and Measurement of Redeemable Securities”, requires
that if registered securities are required to be issued, that maintaining
registration may be outside of the Company’s control. Accordingly, we have
reclassified the Series B Preferred stock into a temporary equity classification
(outside of the general heading of shareholders’ equity) as of October 31, 2005
because we are unable to ensure that registered shares of our common stock
will
be available to pay the redemption price. Notwithstanding the foregoing, it
is
the Company’s intent to convert or pay any potential redemption price on the
Series B Preferred stock through the issuance of our common stock, if
possible.
CRITICAL
ACCOUNTING POLICIES AND ESTIMATES
Revenue
Recognition
We
contract with our customers to perform research and development, manufacture
and
install fuel cell components and power plants under long-term contracts, and
provide services under contract. We recognize revenue on a method similar to
the
percentage-of-completion method.
Revenues
on fuel cell research and development contracts are recognized proportionally
as
costs are incurred and compared to the estimated total research and development
costs for each contract. In many cases, we are reimbursed only a portion of
the
costs incurred or to be incurred on the contract. Revenues 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.
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. As of October 31, 2006, research
and
development sales backlog totaled $30.1 million, of which 28 percent is funded.
Should funding be temporarily delayed or if business initiatives change, we
may
choose to devote resources to other activities, including internally funded
research and development.
Product
sales and revenues include revenues from power plant sales, service contracts,
electricity sales under power purchase agreements (“PPAs”) and incentive
funding. Revenues from power plant sales 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. Revenues from service contracts are generally recognized ratably over
the
contract. For service contracts that include a fuel cell stack replacement,
a
portion of the total contract value is recognized as revenue at the time of
the
stack replacement and the remainder of the contract value is recognized ratably
over the contract. Revenues from electricity sales under power purchase
agreements are recognized as power is produced. Revenues from incentive funding
are recognized ratably over the term of the incentive funding
agreement.
As
our
fuel cell products are in their initial stages of development and market
acceptance, actual costs incurred could differ materially from those previously
estimated. Once we have established that our fuel cell products have achieved
commercial market acceptance and future costs can be reasonably estimated,
then
estimated costs to complete an individual contract, in excess of revenue, will
be accrued immediately upon identification.
Warrant
Value Recognition
Warrants
have been issued as sales incentives to certain of our distribution partners.
These warrants vest as orders from our business partners exceed stipulated
levels. Should warrants vest, or when management estimates that it is probable
that warrants will vest, we record a proportional amount of the fair value
of
the warrants against related revenue as a sales discount.
Inventories
During
the procurement and manufacturing process of a fuel cell power plant, costs
for
material, labor and overhead are accumulated in raw materials and
work-in-process inventory until they are transferred to a customer contract,
at
which time they are recorded in cost of sales.
Our
inventories and advance payments to vendors are stated at the lower of cost
or
market price. As we currently sell products at or below cost, we provide for
a
lower of cost or market (“LCM”) adjustment to the cost basis of inventory and
advances to vendors. This adjustment is computed by comparing the current sales
prices of our power plants to estimated costs of completed power plants. In
certain circumstances, for long-lead time items, we will make advance payments
to vendors for future inventory deliveries, which are recorded as a component
of
other current assets on the consolidated balance sheet.
As
of
October 31, 2006 and October 31, 2005, the LCM adjustment to the cost basis
of
inventory and advance payments to vendors was approximately $11.3 million and
$8.0 million, respectively, which equates to a reduction of approximately 43
and
39 percent, respectively, of the gross inventory value. As of October 31, 2006,
our gross inventory and advances to vendors’ balances increased from the October
31, 2005 balances which resulted in higher gross reserve balances. As inventory
levels increase or decrease, appropriate adjustments to the cost basis are
made.
Internal
Research and Development Expenses
We
conduct internally funded research and development activities to improve current
or anticipated product performance and reduce product life-cycle costs. These
costs are classified as research and development expenses on our consolidated
statements of operations.
Share-Based
Compensation
On
November 1, 2005, we adopted Statement of Financial Accounting Standard No.
123R, “Share-Based Payments” (SFAS 123R). Share-based payment transactions with
employees, which primarily consist of stock options, and third parties requires
the application of a fair value methodology that involves various assumptions.
The fair value of our options awarded to employees is estimated on the date
of
grant using the Black-Scholes option valuation model that uses the following
assumptions: expected life of the option, risk-free interest rate, expected
volatility of our common stock price and expected dividend yield. We estimate
the expected life of the options using historical data and the volatility of
our
common stock is estimated based on a combination of the historical volatility
and the implied volatility from traded options. Share-based compensation of
$4.4
million was recognized in the consolidated statement of operations for the
fiscal year ended October 31, 2006. Refer to Note 14 of the consolidated
financial statements for additional information.
RESULTS
OF OPERATIONS
Management
evaluates the results of operations and cash flows using a variety of key
performance indicators. Indicators that management uses include 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, 2006 and October 31,
2005
Revenues
and costs of revenues
The
following tables summarize our revenue mix for the years ended October 31,
2006
and 2005 (dollar amounts in thousands), respectively:
|
|
Year
Ended
October
31, 2006
|
|
Year
Ended
October
31, 2005
|
|
Percentage
Increase / (Decrease) in Revenues
|
|
|
|
Revenues
|
|
Percent of
Revenues
|
|
Product
Revenues
|
|
Percent of
Revenues
|
|
Revenues:
|
|
|
|
|
|
|
|
|
|
Product
sales and revenues
|
|
$
|
21,514
|
|
|
65
|
%
|
$
|
17,398
|
|
|
57
|
%
|
|
24
|
%
|
Research
and development contracts
|
|
|
11,774
|
|
|
35
|
%
|
|
12,972
|
|
|
43
|
%
|
|
(9
|
)%
|
Total
|
|
$
|
33,288
|
|
|
100
|
%
|
$
|
30,370
|
|
|
100
|
%
|
|
10
|
%
|
|
|
Year
Ended
October
31, 2006
|
|
Year
Ended
October
31, 2005
|
|
Percentage
Increase /
(Decrease)
in
Costs of Revenues
|
|
|
|
Costs
of
Revenues
|
|
Percent of
Costs of
Revenues
|
|
Costs
of
Revenues
|
|
Percent of
Costs of
Revenues
|
|
Cost
of revenues:
|
|
|
|
|
|
|
|
|
|
Product
sales and revenues
|
|
$
|
61,526
|
|
|
86
|
%
|
$
|
52,067
|
|
|
80
|
%
|
|
18
|
%
|
Research
and development contracts
|
|
|
10,330
|
|
|
14
|
%
|
|
13,183
|
|
|
20
|
%
|
|
(22
|
%)
|
Total
|
|
$
|
71,856
|
|
|
100
|
%
|
$
|
65,250
|
|
|
100
|
%
|
|
10
|
%
|
Total
revenues for the year ended October 31, 2006 increased by $2.9 million, or
10
percent, to $33.3 million from $30.4 million during the same period last year.
Components of revenues and costs of revenues are as follows:
Product
sales and revenues
Product
sales and revenue increased
$4.1 million to $21.5 million for fiscal 2006, compared to $17.4 million for
fiscal 2005. Product sales and revenue
for 2006 included approximately $13.0 million of power plant sales, $5.0 million
related to service agreements and component sales and approximately $3.5 million
of revenue related to power purchase agreements. The increase in product sales
and revenues is primarily due to increased market share in the California market
as well as to the timing of customer delivery requirements on new and existing
backlog, an increase in both electricity and grant incentive revenues on power
purchase agreements as more units are operating in the field and higher revenues
on service agreements and stack components also due to a larger operating fleet
of units compared to the prior year.
Cost
of
product sales and revenues increased to $61.5 million during fiscal 2006,
compared to $52.1 million during fiscal 2005.
Included
in cost of sales during 2006 was a non-cash fixed asset impairment charge of
$0.6 million related to the pending sale as of October 31, 2006 of a power
plant
operating under a power purchase agreement. This sale was completed in December
2006. Included in cost of sales during 2005 was
a
non-cash fixed asset impairment charge totaling $1.0 million. This was related
to a planned change in manufacturing processes expected to increase electrical
output for improved product performance and reduced cost in future periods.
The
ratio
of product cost to sales improved to 2.9-to-1 during fiscal 2006 from 3.0-to-1
during fiscal 2005. The improvement in the cost ratio primarily reflects a
decrease in the average cost of our DFC power plants, offset by short-term
pressure on selling prices in California due to higher natural gas pricing,
delays in the Connecticut Renewable Portfolio Standards program and higher
after-market costs on a larger installed fleet.
Our
products do not ship on an even production schedule. The shipment date to
customers depends on a number of factors that are outside of our control,
including siting requirements, timing of construction and permits. We do not
have the sales or order history to quantify trends as of yet.
We
expect
to continue to sell our DFC products at prices lower than our production costs
until such time as we are able to reduce product costs through our engineering
and manufacturing efforts and production volumes increase.
Research
and development contracts
Research
and development revenue decreased
$1.2 million to $11.8 million for fiscal 2006, compared to $13.0 million for
fiscal 2005.
Cost of
research and development contracts decreased to $10.3 million during fiscal
2006, compared to $13.2 million for fiscal 2005.
Research
and development contract revenue and costs were primarily related to SOFC
development under the DOE’s Solid State Energy Conversion Alliance Program, the
Ship Service Fuel Cell contract with the U.S. Navy and the combined cycle Direct
FuelCell/Turbine® development under DOE’s Vision 21 program. The ratio of
research and development cost to revenue improved to 0.9-to-1 from 1.0-to-1
over
the same period a year ago due to the current mix of cost share contracts.
Administrative
and selling expenses
Administrative
and selling expenses increased by $3.6 million to $17.8 million during fiscal
2006, compared to $14.2 million in fiscal 2005. This increase is primarily
due
to share-based compensation of approximately $2.6 million resulting from the
adoption of SFAS 123R, higher salaries as a result of increased headcount and
higher professional costs resulting from commercial market development and
increased proposal activity for research and development and commercial
contracts.
Research
and development expenses
Research
and development expenses increased to $24.7 million during fiscal 2006, compared
to $21.8 million recorded in fiscal 2005. The
increase is
due to
development costs for sub-MW and MW cost reduction, including recent
achievements in advanced cell stack design that increases the power output
of
our power plants by 20 percent, costs related to our efforts to extend stack
life from the current three years to five years and longer and $0.8 million
of
share-based compensation resulting from the adoption
of SFAS 123R.
Loss
from operations
The
net
result of our revenues and costs was a loss from operations for fiscal 2006
totaling $81.0 million. This operating loss is approximately 14 percent higher
than the $70.9 million loss recorded in fiscal 2005. Operating loss was
higher primarily from increased product losses on higher revenue, an increase
in
administrative and selling expenses and research and development expenses as
discussed above.
Other
factors impacting the operating loss included development of our distribution
network, increases in depreciation on new production equipment, business
insurance premiums, information systems and infrastructure development. We
expect to incur operating losses in future reporting periods as we continue
to
participate in government cost share programs, sell products
at prices lower than our current production costs, and
invest in our “cost out” initiatives.
Loss
from equity investments
Our
investment in Versa totaled approximately $11.5 million and $12.3 million as
of
October 31, 2006 and 2005, respectively. Our current ownership interest is
39%
and we account for our investment in Versa under the equity method of
accounting. Our share of equity losses for fiscal 2006 and 2005 were $0.9
million and $1.6 million, respectively.
In
April
2006, we entered into an agreement to sell our equity investment in Everplore
Technology (Xiamen) Co. and recognized a gain of approximately $37 thousand,
which offset losses from equity investments.
Interest
and other income, net
Interest
and other income, net, was $6.0 million for fiscal 2006, compared
to $5.5 million for fiscal 2005.
Interest
and other income increased due to higher average yields on invested balances,
partially offset by lower state research and development tax credits, which
totaled $0.2 million and $0.5 million for 2006 and 2005,
respectively.
Discontinued
operations, net of tax
There
were no discontinued operations in fiscal 2006. During fiscal 2005, we exited
certain facilities in Canada and as a result recorded fixed asset impairment
charges totaling approximately $0.9 million and approximately $0.4 million
of
exit costs related to these facilities. This resulted in total loss from
discontinued operations of approximately $1.3 million.
Provision
for income taxes
We
believe that due to our efforts to commercialize our DFC technology, we will
continue to incur losses. Based on projections for future taxable income over
the period in which the deferred tax assets are realizable, management believes
that significant uncertainty exists surrounding the recoverability of the
deferred tax assets. Therefore, no tax benefit has been recognized related
to
current or prior year losses and other deferred tax assets.
Comparison
of the Years Ended October 31, 2005 and October 31,
2004
Revenues
and costs of revenues
The
following tables summarize our revenue and cost mix for the years ended October
31, 2005 and 2004 respectively (dollar amounts in thousands):
|
|
Year
Ended
October
31, 2005
|
|
Year
Ended
October
31, 2004
|
|
Percentage
Increase /
|
|
|
|
Revenues
|
|
Percent of
Revenues
|
|
Product
Revenues
|
|
Percent of
Revenues
|
|
(Decrease) in
Revenues
|
|
Revenues:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Product
sales and revenues
|
|
$
|
17,398
|
|
|
57 |
% |
$ |
12,636 |
|
|
40 |
% |
|
38
|
%
|
Research
and development contracts
|
|
|
12,972
|
|
|
43 |
% |
|
18,750
|
|
|
60 |
% |
|
(31
|
)%
|
Total
|
|
$
|
30,370
|
|
|
100 |
% |
$ |
31,386 |
|
|
100 |
% |
|
(3
|
%)
|
|
|
Year
Ended
October
31, 2005
|
|
Year
Ended
October
31, 2004
|
|
Percentage
Increase /
|
|
|
|
Costs
of
Revenues
|
|
Percent of
Costs of
Revenues
|
|
Costs
of
Revenues
|
|
Percent of
Costs of
Revenues
|
|
(Decrease)
in
Costs of Revenues
|
|
Cost
of revenues:
|
|
|
|
|
|
|
|
|
|
|
|
Product
sales and revenues
|
|
$
|
52,067
|
|
|
80 |
% |
$ |
39,961 |
|
|
59 |
% |
|
30
|
%
|
Research
and development contracts
|
|
|
13,183
|
|
|
20 |
% |
|
27,290 |
|
|
41 |
% |
|
(52
|
%)
|
Total
|
|
$
|
65,250
|
|
|
100 |
% |
$ |
67,251 |
|
|
100 |
% |
|
(3
|
%)
|
Total
revenues for the year ended October 31, 2005 decreased by $1.0 million, or
3
percent, to $30.4 million from $31.4 million during the same period last year.
The components of our revenues and cost of revenues are further described as
follows:
Product
sales and revenues and product costs
Product
sales were $17.4 million for fiscal 2005, compared to $12.6 million in fiscal
2004. The increase in product sales and revenues is primarily due to increased
manufacturing of power plants for the County of Alameda (Santa Rita Jail),
Logan
Energy, MTU CFC and recognition of electricity and grant revenue related to
power purchase agreements. Product sales backlog totaled approximately $26.4
million as of both October 31, 2005 and 2004. Included in these figures are
$6.1
million and $1.6 million for 2005 and 2004, respectively, related to long-term
service agreements. Product backlog does not include power purchase or incentive
funding agreements.
Product
costs were higher with increased revenue to $52.1 million for the year ended
October 31, 2005, compared to $40.0 million in the same period of a year ago.
Included in cost of sales during 2005 was a non-cash fixed asset impairment
charge totaling $1.0 million. This was related to a planned change in
manufacturing processes expected to increase electrical output for improved
product performance and reduced costs in future periods. The ratio of costs
to
revenue decreased to approximately 3.0-to-1 in 2005 from approximately 3.2-to-1
in 2004. This ratio is inclusive of any LCM adjustments in cost of sales related
to power plants for power purchase agreements. Costs related to power purchase
agreements were $10.3 million and $3.1 million for the fiscal years ended
October 31, 2005 and 2004, respectively. Excluding the non-cash fixed asset
impairment charge and power purchase agreement costs, our cost ratios would
have
been approximately 2.4-to-1 and approximately 2.7-to-1 for the fiscal years
ended October 31, 2005 and 2004, respectively. The ratio of costs to product
sales improved from the same period of a year ago as we recognized savings
from
our cost-out program. The cost ratios included above that exclude certain
non-cash items are not considered generally accepted accounting principles
(“GAAP”) financial measures and should not be considered as a substitute for, or
superior to, measures of financial performance prepared in accordance with
GAAP.
We have used non-GAAP pro forma financial measures in analyzing financial
results because they provide meaningful information regarding our operational
performance and facilitate management’s internal comparisons to our historical
operating results and comparisons to competitors’ operating results.
Our
products do not ship on an even production schedule. The shipment date to
customers depends on a number of factors that are outside of our control,
including siting requirements, timing of construction and permits. We do not
have the sales or order history to quantify sufficient trends as of
yet.
Research
and development contracts
Revenue
from research and development contracts will vary from year to year depending
on
government funding levels, new contracts and work on existing contracts. Revenue
from research and development contracts decreased 31 percent during fiscal
2005
to $13.0 million from $18.8 million in fiscal 2004.
Revenues
decreased with the completion of the DOE’s Product Design Improvement program
(“PDI”) program and the Bath Iron Works contract. Revenues were also lower on
the DOE’s Clean Coal contract and other U.S. Navy contracts compared to the
prior year. These decreases were partially offset by an increase in revenue
related to the DOE’s SECA
program.
The
cost
of research and development contract revenue declined by $14.1 million for
fiscal 2005, compared to fiscal 2004, due to reduced costs on the Clean Coal
contract, the
PDI
program, U.S. Navy contracts and King County
contracts. The ratio of research and development cost to revenue was
approximately 1.0-to-1 in 2005, compared to approximately 1.5-to-1 in 2004
due
to the substantial completion of the Clean Coal and King County contracts,
which
had significant cost share commitments. The Clean Coal DFC3000 power plant
was
not operated at the Indiana site due to fuel supply issues and was removed
upon
receiving approval from the DOE.
Administrative
and selling expenses
Administrative
and selling expenses decreased by $0.7 million or 5 percent, to $14.2 million
in
fiscal 2005, compared to $14.9 million in fiscal 2004. This decrease is
primarily the result of the disposition of Canadian operations with costs
totaling $1.2 million in 2004, partially offset by higher sales and proposal
costs for multi-megawatt projects of approximately $0.2 million and higher
administrative costs related to Sarbanes-Oxley Act compliance totaling
approximately $0.4 million.
Research
and development expenses
Research
and development expenses decreased to $21.8 million during fiscal 2005, compared
to $26.7 million for fiscal 2004. This decrease is the result of the disposition
of Canadian operations with costs totaling approximately $9.1 million, partially
offset by increased internal research and development related to support of
our
DFC 300 products and our cost-out program totaling approximately $5.4
million.
Purchased
in-process research and development
The
$12.2
million in-process research and development (“IPR&D”) charge relates to SOFC
technology acquired in the Global transaction. In 1997, Global began developing
SOFC technology, which is still in development. The $12.2 million allocated
to
IPR&D was determined using two established valuation techniques. An average
of the cost valuation and market valuation approaches were used to determine
the
IPR&D amount. The amounts estimated in this valuation were calculated using
a risk-adjusted discount rate of 30 percent. As the acquired technology has
not
yet reached technological feasibility and no alternative future uses existed,
it
was expensed upon acquisition in accordance with Statement of Financial
Accounting Standards (“SFAS”) No. 2, “Accounting for Research and Development
Costs.”
The
IPR&D acquired was related to one project, the development of a solid oxide
fuel cell. Prior to the transaction date, Global spent approximately five years
developing this technology. In 2003, we received notice of an award to
participate in the DOE’s ten-year SECA program to develop low cost solid oxide
fuel cells for residential, commercial, and light industrial applications.
The
SECA program is a cost-share program totaling approximately $139 million which
has three phases. This technology was subsequently sold to our partner in the
SECA program, Versa, along with fixed assets in exchange for Versa stock. We
currently estimate that it will take approximately five to ten years to complete
the development.
Loss
from operations
The
loss
from operations for the year ended October 31, 2005 totaled $70.9 million
compared to the loss of $89.6 million recorded in 2004. This decrease of
approximately 21 percent is due primarily to the acquisition related charge
of
purchased in-process research and development in the prior year totaling $12.2
million, lower cost ratios for both research and development contracts and
product sales and the disposition of our Canadian operations. We expect to
incur
operating losses in future reporting periods as we continue to participate
in
government cost share programs, sell products
at prices lower than our current production costs, and
invest in our cost-out initiatives.
Loss
from equity investments
Our
investment in Versa totaled approximately $12.3 million and $2.0 million as
of
October 31, 2005 and 2004, respectively. We began accounting for this investment
under the equity method of accounting as of November 1, 2004, at which time
our
ownership had increased from 16 percent to 42 percent. As a result of additional
capital contributions by other shareholders during 2005, our ownership interest
decreased to 41 percent as of October 31, 2005. Our share of equity losses
for
fiscal 2005 totaled approximately $1.6 million.
Interest
and other income, net
Interest
and other income, net, increased by $3.1 million when comparing the fiscal
year
ended October 31, 2005 to the prior year. The increase is due to higher yields
on higher investment balances and state research and development tax credits
totaling $0.5 million.
Provision
for income taxes
We
believe, that due to our efforts to commercialize our DFC technology, we will
continue to incur losses. Based on projections for future taxable income over
the period in which the deferred tax assets are realizable, management believes
that significant uncertainty exists surrounding the recoverability of the
deferred tax assets. Therefore, no tax benefit has been recognized related
to
current year losses and other deferred tax assets. We pay franchise and capital
taxes in certain states, which are classified as a component of administrative
and selling expenses.
Discontinued
operations, net of tax
During
the fiscal year ended October 31, 2005, we exited certain facilities in Canada
and as a result recorded fixed asset impairment charges totaling approximately
$0.9 million and exit costs of approximately $0.4 million. During the fiscal
year ended October 31, 2004, we acquired Global and subsequently divested its
generator business unit through the sale of Global on May 28, 2004. As a result,
historical results were reclassified as discontinued operations. Income, net
of
taxes, related to the generator business totaled approximately $0.8 million
for
fiscal 2004.
LIQUIDITY
AND CAPITAL RESOURCES
We
had
approximately $120.6 million of cash, cash equivalents and investments as of
October 31, 2006, compared to $180.0 million as of October 31, 2005.
Net
cash
and investments used during fiscal 2006 was $59.4 million. Cash and investments
used during fiscal 2006 include dividend payments on our preferred stock of
$8.9
million (includes $4.3 million related to the conversion of 41,755 shares of
Series B Preferred Stock), offset by proceeds from the issuance of common stock
of $8.0 million, proceeds from common stock issued for option and stock purchase
plans of $1.4 million and receipt of incentive funding related to our power
purchase agreements of $6.6 million.
Cash
Inflows and Outflows
Cash
and
cash equivalents as of October 31, 2006 totaled $26.2 million, reflecting an
increase of $3.5 million from the balance reported as of October 31, 2005.
The
key components of our cash inflows and outflows from continuing operations
were
as follows:
Operating
Activities:
During
fiscal 2006, we used $48.4 million in cash for operating activities, compared
to
operating cash usage of $56.0 million during fiscal 2005. Cash used in operating
activities during fiscal 2006 consists of a net loss for the period of
approximately $76.1 million, offset by non-cash adjustments totaling $15.4
million, including $4.4 million of share-based compensation and depreciation
and
amortization expense of $9.6 million.
In
addition, cash provided by working capital totaled approximately $12.3 million,
including lower accounts receivable of $0.8 million due to the timing of
production and shipping milestones, higher deferred revenue of approximately
$5.6 million primarily related to incentive funds received for PPAs, higher
accounts payable and accrued liabilities of $7.0 million due to increased
production. These amounts were partially offset by an increase in inventories
of
approximately $2.0 million, due to higher production levels.
Investing
Activities: During
fiscal 2006, net cash provided by investing activities totaled $51.8 million,
compared with net cash used of approximately $63.9 million in fiscal 2005.
Capital expenditures totaled $11.3 million for 2006. This included approximately
$7.3 million for equipment being built for power purchase agreements. During
fiscal 2006, approximately $202.8 million of investments in U.S. Treasury
Securities matured and new treasury purchases totaled $139.7 million.
Financing
Activities: During
fiscal 2006, net cash provided by financing activities was approximately $0.2
million, compared to $96.8 million in fiscal 2005. Fiscal 2005 included $99.0
million of net proceeds from the sale of the Series B Preferred stock. For
fiscal 2006, cash provided by financing activities related to net proceeds
from
the sale of common stock of approximately $8.0 million and proceeds from
employee stock option exercises of approximately $1.4 million. This was offset
by the payment of dividends on our Series 1 and Series B Preferred Stock of
approximately $8.9 million, including $4.3 million related to the conversion
of
41,755 shares of Series B Preferred Stock.
Sources
and Uses of Cash and Investments
We
continue to invest in new product development and bringing our products to
market and, as such, we are not currently generating positive cash flow from
our
operations. Our operations are funded primarily through sales of equity
securities and cash generated from customer contracts, including cash from
government research and development contracts, product sales, power purchase
agreements and incentive funding and interest earned on investments. Our future
cash requirements depend on numerous factors including future involvement in
research and development contracts, implementing our cost reduction efforts
and
increasing annual order volume.
Future
involvement in research and development contracts
Our
research and development contracts are generally multi-year, cost reimbursement
type contracts. The majority of these are U.S. Government contracts that
are dependent upon the government’s 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. To obtain these contracts,
we must continue to prove the benefits of our technologies and be successful
in
our competitive bidding.
Implementing
cost reduction efforts on our fuel cell products
Cost
reduction is critical to attaining profitability in future periods and is
essential for us to penetrate the market for our fuel cell products. Cost
reductions will reduce and/or eliminate the need for incentive funding programs
that are currently available to allow our product pricing to better compete
with
grid-delivered power and other distributed generation technologies. Our
multi-disciplined cost reduction program focuses on value engineering,
manufacturing process improvements, and technology improvements to increase
power plant output and efficiency.
Our
2 MW
Santa Clara ‘proof-of-concept’ project in 1996-1997 cost more than $20,000/kW to
produce. In 2003, we shipped our first commercial product, a DFC300 to the
Kirin
Brewery which cost more than $10,000/kW. At that time, we implemented our
commercial cost-out program hiring additional engineers who focused on reducing
the total life cycle costs of our power plants. Since 2003, they have made
significant progress primarily through value engineering our products and
increasing the power output by 20%. Our current manufactured cost is
approximately $3,250 /kW on our multi-MW power plant, $4,300/kW on our MW
plant
and $4,800/kW for the sub-MW product. As these products are produced in 2007,
we
expect to realize these manufactured costs in our financial statements.
In
2006,
we primarily focused our cost saving efforts on our multi-MW product, the
DFC3000. Significant savings came from “value engineering” -- developing
lower-cost designs for various elements of the power plant -- and improving
the
efficiency of the Company’s manufacturing, testing and commissioning processes.
The cost reduction also resulted from the 20 percent increase in power output
in
our DFC products announced in August 2006. By improving thermal management
of
electrochemical activity within the stack, the Company increased the power
output from each cell, which produces more electricity from the same basic
power
plant components.
FuelCell
Energy will continue to emphasize its cost out initiatives to deliver the
most
cost efficient and environmentally friendly power generation solutions and
meet
the needs of the emerging RPS markets. In 2007, the DFC300MA and DFC1500MA
are
targeted to achieve another 20 percent cost reduction through improvements
in
strategic sourcing, value engineering and operations. Increased production
volume could also reduce that cost another 10 to 20 percent.
Increasing
annual order volume
In
addition to the cost reduction initiatives discussed above, we need to increase
annual order volume. Increased production volumes are necessary to lower costs
by leveraging supplier/purchasing opportunities, incorporating manufacturing
process improvements and spreading fixed costs over higher units of production.
Our manufacturing and conditioning facilities have the equipment in place to
accommodate 50 MW of annual production volume, but the higher production volume
will require increasing the manufacturing workforce.
We
currently have 8.05 MW in backlog and we have limited visibility into future
order volume. In Connecticut, we have partnered with multiple developers to
submit 98.6 MW of proposals for large-scale multi-MW projects to be submitted
in
round two under Connecticut’s RPS Program, Project 100. California is a leading
market for renewable/ultraclean products, approximately 30 percent of our
installed capacity is in California and the state has made available
approximately $80 million of funding in 2007.
With
our
currently achieved and projected annual cost reduction targets, we believe
we
can reach gross margin break-even on product sales at a sustained annual order
and production volume of approximately 35 MW to 50 MW, depending on product
mix,
geographic location and other variables such as fuel prices. We believe that
Company net income break-even can be achieved at a sustained annual order and
volume production of approximately 75-100 MW assuming a mix of sub-MW and MW
sales. If this mix trends more toward MW and multi-MW orders, we believe that
the gross margin and net income break-even volumes can be lower.
Our
fiscal 2005 production volume was approximately 6 MW and our 2006 volume was
approximately 9 MW. Our current production volume is 10MW. Depending on customer
demand and emergence of the RPS market, our production rates will be adjusted
accordingly.
We
anticipate that our existing capital resources, together with anticipated
revenues will be adequate to satisfy our planned financial requirements and
agreements through at least the next twelve months.
Commitments
and Significant Contractual Obligations
A
summary
of our significant future commitments and contractual obligations as of October
31, 2006 and the related payments by fiscal year is summarized as follows (in
thousands):
|
|
Payments
Due by Period
|
|
|
|
Total
|
|
Less
than
1
Year
|
|
1
- 3
Years
|
|
3
- 5
Years
|
|
More
than
5
Years
|
|
Contractual
Obligation:
|
|
|
|
|
|
|
|
|
|
|
|
Capital
and Operating lease commitments
(1)
|
|
$
|
2,920
|
|
$
|
776
|
|
$
|
1,546
|
|
$
|
598
|
|
$
|
—
|
|
Term
loans (principal and interest)
|
|
|
751
|
|
|
441
|
|
|
309
|
|
|
1
|
|
|
—
|
|
Purchase
commitments(2)
|
|
|
29,113
|
|
|
27,690
|
|
|
1,328
|
|
|
19
|
|
|
76
|
|
Series
I Preferred dividends payable
(3)
|
|
|
20,009
|
|
|
379
|
|
|
758
|
|
|
10,349
|
|
|
8,523
|
|
Series
B Preferred dividends payable
(4)
|
|
|
10,464
|
|
|
3,206
|
|
|
6,412
|
|
|
846
|
|
|
—
|
|
Totals
|
|
$
|
63,257
|
|
$
|
32,492
|
|
$
|
10,353
|
|
$
|
11,813
|
|
$
|
8,599
|
|
(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) |
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 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, Inc., the holder of the Series 1 preferred shares, so
long as
Enbridge holds the shares. Interest accrues on cumulative unpaid
dividends
at a 2.45 percent quarterly rate, compounded quarterly, until payment
thereof. Cumulative unpaid dividends and interest at October 31,
2006 were
approximately $5.3 million. For the purposes of this disclosure,
we have
assumed that the minimum dividend payments would be made through
2010. In
2010, we would be required to pay any unpaid and accrued dividends.
Subsequent to 2010, we would be required to pay annual dividend amounts
totaling Cdn.$1.25 million. We have the option of paying these dividends
in stock or cash.
|
(4) |
Dividends
on Series B Preferred Stock accrue at an annual rate of 5% paid quarterly.
The obligations schedule assumes we will pay preferred dividends
on these
shares through November 20, 2009, at which time the preferred shares
may
be subject to mandatory conversion at the option of the Company.
|
On
June
29, 2000, we entered into a loan agreement, secured by machinery and equipment,
and have borrowed an aggregate of $2.2 million under the agreement. The loan
is
payable over eight years, with payments of interest only for the first six
months and then repaid in monthly installments with interest computed annually
based on the ten-year U.S. Treasury note plus 2.5 percent. Our current interest
rates at October 31, 2006 is 7.6 percent and the outstanding principal balance
on this loan is approximately $0.7 million
Approximately
$0.8 million of our cash and cash equivalents have been pledged as collateral
for certain banking relationships in which we participate.
Research
and Development Cost-Share Contracts
We
have
contracted with various government agencies as either a prime contractor or
sub-contractor on cost-share contracts and agreements. Cost-share terms require
that participating contractors share the total cost of the project based on
an
agreed upon ratio with the government agency. As of October 31, 2006, our
research and development sales backlog totaled $30.1 million. As this backlog
is
funded in future periods, we will incur additional research and development
cost-share related to this backlog totaling approximately $17.9 million for
which we would not be reimbursed by the government.
Product
Sales Contracts
Our
fuel
cell power plant products are in the initial stages of development and market
acceptance. As such, costs to manufacture and install our products exceed
current market prices. As of October 31, 2006, we had product sales backlog
of
approximately $18.1 million. We do not expect sales from this backlog to be
profitable.
Long-term
Service Agreements
We
have
contracted with certain customers to provide service for fuel cell power plants
ranging from one to thirteen years. Under the provisions of these contracts,
we
provide services to maintain, monitor and repair customer power plants. In
some
contracts we provide for replacement of fuel cell stacks. Pricing for service
contracts is based upon estimates of future costs, which given our products
early stage of development could be materially different from actual expenses.
As of October 31, 2006, we had a service agreement sales backlog of
approximately $9.8 million.
Power
Purchase Agreements
Power
purchase agreements (PPAs) are a common arrangement in the energy industry,
whereby a customer purchases energy from an owner and operator of the power
generation equipment. A number of our partners enter into PPAs with end use
customers, such as Marubeni in Japan and PPL in the U.S., where they purchase
DFC power plants from us, own and operate the units, and recognize revenue
as
energy is sold to the end user.
We
have
seeded the market with a number of Company funded PPAs to penetrate key target
markets and develop operational and transactional experience. With the added
benefit of the federal investment tax credit and accelerated depreciation in
the
Energy Policy Act of 2005, we believe this experience may enable us to attract
third party financing for existing and future projects, including multi-MW
projects. To date, we have funded the development and construction of certain
fuel cell power plants sited near customers in California, and own and operate
assets through PPA entities that we maintain an 80% ownership interest with
Alliance Power, Inc. owning the remaining 20%.
We
have
qualified for incentive funding for these projects in California under the
state’s Self Generation Incentive Funding Program 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. As of October 31, 2006 we had deferred revenue
totaling $9.5 million on the consolidated balance sheet related to incentive
funding received on PPAs.
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 customer’s 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 in these
PPA
entities, 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 in these PPA entities, are carried
at fair value on the consolidated balance sheets 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 PPAs and we have the right to
terminate PPAs by giving written notice to the customer, subject to certain
exit
costs.
As
of
October 31, 2006, we had 3.5 MW of power plants in operation under PPAs ranging
from 5 - 10 years. Another 0.5 MW was placed in operation during November 2006
and in December 2006, we sold a 1 MW power plant that was operating as a PPA
to
the Sierra Nevada Brewing Company and entered into a 5-year long-term service
and planned maintenance agreement.
RECENT
ACCOUNTING PRONOUNCEMENTS
In
December 2004, the Financial Accounting Standards Board (“FASB”) issued SFAS No.
123R (revised 2004), “Share-Based Payment”, which revised SFAS No. 123,
“Accounting for Stock-Based Compensation”. This statement supercedes APB Opinion
No. 25, “Accounting for Stock Issued to Employees.” The revised statement
addresses the accounting for share-based payment transactions with employees
and
other third parties, eliminates the ability to account for share-based
compensation transactions using APB 25 and requires that the compensation costs
relating to such transactions be recognized in the consolidated statement of
operations. The Company adopted this statement as of November 1, 2005 as
required. Refer to Note 14 of Notes to Consolidated Financial Statements for
additional information.
In
November 2004, the FASB issued SFAS No. 151, “Inventory Costs,” which
amends the guidance in Accounting Research Bulletin No. 43, Chapter 4,
“Inventory Pricing,” to clarify the accounting for abnormal amounts of idle
facility expense, freight, handling costs, and wasted material. This Statement
requires that those items be recognized as current-period charges regardless
of
whether they meet the criterion of “so abnormal”. In addition, this Statement
requires that allocation of fixed production overheads to the costs of
conversion be based on the normal capacity of the production facilities. The
Company adopted the provisions of this accounting standard on November 1, 2005,
as required, and there was not a material impact to the Company’s consolidated
financial statements.
In
March 2005, the FASB issued Interpretation No. 47, “Accounting for
Conditional Asset Retirement Obligations, an interpretation of FASB Statement
No. 143” (“FIN 47”). FIN 47 requires the recognition of a liability for the
fair value of a legally-required conditional asset retirement obligation when
incurred, if the liability’s fair value can be reasonably estimated. FIN 47 also
clarifies when an entity would have sufficient information to reasonably
estimate the fair value of an asset retirement obligation. The Company adopted
the provisions of this accounting standard in the fourth quarter of fiscal
2006,
as required, and there was no impact to the Company’s consolidated financial
statements as of October 31, 2006.
In
June
2006, the FASB issued FASB Interpretation No. 48, Accounting for Uncertain
Income Taxes (“FIN 48”). FIN 48 clarifies the accounting for
uncertainty in income taxes recognized in an entity’s financial statements.
FIN 48 prescribes a comprehensive model 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.
FIN 48 is effective for fiscal years beginning after December 16, 2006
(beginning of our fiscal 2008 or November 1, 2007). The Company is currently
evaluating FIN 48 and we do not anticipate that it will have a material impact
on our financial statements upon adoption due to the Company’s current income
tax position.
Item
7A. QUANTITATIVE AND QUALITATIVE DISCLOSURES ABOUT MARKET
RISK
Interest
Rate Exposure
Our
exposures to market risk for changes in interest rates relate primarily to
our
investment portfolio and long term debt obligations. Our investment portfolio
includes both short-term U.S. Treasury instruments with maturities averaging
three months or less, as well as U.S. Treasury notes with fixed interest rates
with maturities of up to twenty months. Cash is invested overnight with high
credit quality financial institutions. Based on our overall interest exposure
at
October 31, 2006, including all interest rate sensitive instruments, a near-term
change in interest rate movements of 1 percent would affect our results of
operations by approximately $0.2 million annually.
Foreign
Currency Exchange Risk
With
our
Canadian business entity, FuelCell Energy, Ltd., we are subject to foreign
exchange risk, although we have taken steps to mitigate those risks where
possible. As of October 31, 2006, approximately $0.8 million (less than one
percent) of our total cash, cash equivalents and investments was in currencies
other than U.S. dollars. The functional currency of FuelCell Energy, Ltd. is
the
U.S. dollar.
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. Consequently, isolating the effect of changes in
currency does not incorporate these other important economic
factors.
Derivative
Fair Value Exposure
As
discussed in more detail within Note 13 of Notes to Consolidated Financial
Statements, we have determined that our Series 1 Preferred shares include
embedded derivatives that require bifurcation from the host contract and
separate accounting in accordance with SFAS 133, Accounting
for Derivative Instruments and Hedging Activities.
Specifically, the embedded derivatives requiring bifurcation from the host
contract are 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 on our Consolidated Balance Sheet as of
October 31, 2006 was $0.2 million. The fair value of these derivatives is 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 will result
in
fluctuations in the derivative value and will impact the consolidated statement
of operations. For example, a 25% increase from the closing price of our common
stock at October 31, 2006 would result in an increase in the fair value of
these
derivatives and a charge to the consolidated statement of operations of
approximately $0.1 million, assuming all other assumptions remain the
same.
Item
8. CONSOLIDATED FINANCIAL STATEMENTS AND SUPPLEMENTARY
DATA
Index
to the Consolidated Financial Statements
|
|
Page
|
|
|
|
Report
of Independent Registered Public Accounting Firm
|
|
67
|
|
|
|
Consolidated
Balance Sheets - October 31, 2006 and 2005
|
|
69
|
|
|
|
Consolidated
Statements of Operations for the Years ended October 31, 2006, 2005
and
2004
|
|
70
|
|
|
|
Consolidated
Statements of Changes in Shareholders’ Equity for the Years ended October
31, 2006, 2005 and 2004
|
|
71
|
|
|
|
Consolidated
Statements of Cash Flows for the Years ended October 31, 2006, 2005
and
2004
|
|
73
|
|
|
|
Notes
to Consolidated Financial Statements
|
|
74
|
|
|
|
Report
of Independent Registered Public Accounting Firm
The
Board
of Directors and Stockholders
FuelCell
Energy, Inc.:
We
have
audited the accompanying balance sheets of FuelCell Energy, Inc. as of October
31, 2006 and 2005, and the related consolidated statements of operations,
changes in shareholders' equity, and cash flows for each of the years in the
three-year period ended October 31, 2006. We also have audited management's
assessment, included in the accompanying Management’s Annual Report on Internal
Control Over Financial Reporting, that FuelCell Energy, Inc. and subsidiaries
maintained effective internal control over financial reporting as of October
31,
2006, 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. Our responsibility is to express an opinion on these
consolidated financial statements, an opinion on management's assessment, and
an
opinion on the effectiveness of the Company's 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 audit of 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, evaluating
management's assessment, testing and evaluating the design and operating
effectiveness of internal control, and performing such other procedures as
we
considered necessary in the circumstances. We believe that our audits provide
a
reasonable basis for our opinions.
A
company's 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 company's 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 company's
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. as
of
October 31, 2006 and 2005, and the results of its operations and its cash flows
for each of the years in the three-year period ended October 31, 2006, in
conformity with U.S. generally accepted accounting principles. Also, in our
opinion, management's assessment that FuelCell Energy, Inc. maintained effective
internal control over financial reporting as of October 31, 2006, is fairly
stated, in all material respects, based on criteria established in Internal
Control—Integrated Framework issued by the Committee of Sponsoring Organizations
of the Treadway Commission (COSO). Furthermore, in our opinion, FuelCell Energy,
Inc. maintained, in all material respects, effective internal control over
financial reporting as of October 31, 2006, based on criteria established in
Internal Control—Integrated Framework issued by the Committee of Sponsoring
Organizations of the Treadway Commission (COSO).
As
discussed in Notes 1 and 14 to the consolidated financial statements, the
Company changed its method of accounting for share-based payments as of November
1, 2005.
/s/
KPMG LLP
January
12, 2007
Hartford,
Connecticut
FUELCELL
ENERGY, INC.
Consolidated
Balance Sheets
(Dollars
in thousands, except share and per share amounts)
|
|
October
31, 2006
|
|
October
31, 2005
|
|
ASSETS
|
|
|
|
|
|
Current
assets:
|
|
|
|
|
|
Cash
and cash equivalents
|
|
$
|
26,247
|
|
$
|
22,702
|
|
Investments:
U.S. treasury securities
|
|
|
81,286
|
|
|
113,330
|
|
Accounts
receivable, net of allowance for
doubtful
accounts of $43 and $104, respectively
|
|
|
9,402
|
|
|
10,062
|
|
Inventories,
net
|
|
|
14,121
|
|
|
12,141
|
|
Other
current assets
|
|
|
2,653
|
|
|
3,659
|
|
Total
current assets
|
|
|
133,709
|
|
|
161,894
|
|
|
|
|
|
|
|
|
|
Property,
plant and equipment, net
|
|
|
48,136
|
|
|
46,705
|
|
Investments:
U.S. treasury securities
|
|
|
13,054
|
|
|
43,928
|
|
Equity
investments
|
|
|
11,483
|
|
|
12,473
|
|
Other
assets, net
|
|
|
270
|
|
|
520
|
|
Total
assets
|
|
$
|
206,652
|
|
$
|
265,520
|
|
|
|
|
|
|
|
|
|
LIABILITIES
AND SHAREHOLDERS’ EQUITY
|
|
|
|
|
|
|
|
Current
liabilities:
|
|
|
|
|
|
|
|
Current
portion of long-term debt and other liabilities
|
|
$
|
653
|
|
$
|
503
|
|
Accounts
payable
|
|
|
12,508
|
|
|
6,221
|
|
Accrued
liabilities
|
|
|
6,418
|
|
|
7,018
|
|
Deferred
license fee income
|
|
|
38
|
|
|
38
|
|
Deferred
revenue and customer deposits
|
|
|
8,224
|
|
|
7,378
|
|
Total
current liabilities
|
|
|
27,841
|
|
|
21,158
|
|
|
|
|
|
|
|
|
|
Long-term
deferred revenue
|
|
|
6,723
|
|
|
1,988
|
|
Long-term
debt and other liabilities
|
|
|
678
|
|
|
904
|
|
Total
liabilities
|
|
|
35,242
|
|
|
24,050
|
|
Redeemable
minority interest
|
|
|
10,665
|
|
|
11,517
|
|
Redeemable
preferred stock ($0.01 par value, liquidation preference of
$64,120
and $105,875 at October 31, 2006 and 2005, respectively.)
|
|
|
59,950
|
|
|
98,989
|
|
|
|
|
|
|
|
|
|
Shareholders’
equity:
|
|
|
|
|
|
|
|
Common
stock ($.0001 par value); 150,000,000 shares authorized at
October
31, 2006 and October 31, 2005; 53,130,901 and 48,497,088
shares
issued and outstanding at October 31, 2006 and October 31,
2005,
respectively.
|
|
|
5
|
|
|
5
|
|
Additional
paid-in capital
|
|
|
470,045
|
|
|
424,472
|
|
Accumulated
deficit
|
|
|
(369,255
|
)
|
|
(293,513
|
)
|
Treasury
stock, Common, at cost (15,583 shares in 2006
and
4,279 shares in
2005)
|
|
|
(158
|
)
|
|
(44
|
)
|
Deferred
compensation
|
|
|
158
|
|
|
44
|
|
Total
shareholders’ equity
|
|
|
100,795
|
|
|
130,964
|
|
|