Stephen Clarke
Analyst · Oppenheimer & Co
Now before moving to the agenda for today's call, I want to summarize the progress we've made since Tom, Selwyn and I, cofounded Aqua Metals. And you can see the bullet points on the image there, they largely speak for themselves. After a period of founder funder [indiscernible] development, we closed our first external funding in quarter 4, 2014. We went on to get our first full scale electrolyzer up and running by quarter 1, 2015, following that with an IPO and starting construction of our first facility. To the surprise of many in our industry, we secured our key permits in quarter 3 and quarter 4 of 2016, and our first facility was determined not to be subject to NESHAP, which was an important precedent. At the start of 2017, we secured an important strategic partnership with Johnson Controls, JCI, and secured key patents in the second half of 2017.
As we reported, we hit a roadblock in the form of sticky lead, and I'm going to explain sticky lead in a few minutes. And we overcame that through science, engineering, hard work and long days. And as we have reported, we solved that issue and daytime operation of a single electrolyzer featured with what we call the sticky lead fix kit began in quarter 4, 2017.
That's continued and daytime operation of 1 complete electrolyzer module -- sorry, one complete 6 electrolyzer module or 6 electrolyzers per module, each fitted with the same sticky lead fixed kit, began in this quarter, and we recently announced our first 24-hour run of that module. The rest of this presentation will continue this theme of progress and perseverance.
For the agenda for the presentation today, I'm going to focus on operations update, starting off with sticky lead, what is it and how we fixed it. And I'm going to talk about the ramp-up of production at our Tahoe Reno Industrial complex base facility. I'm going to talk a little bit about intellectual property, I'm going to hand over to Tom, who will take us through the financials, and then I'll summarize.
So that's the agenda for today. So sticky lead. What is it? There is a photograph on the right of the slide there, and that photograph means, it will be a video and it pretty much shows a phenomenon. Simply put, the lead that we produced with [ stop ] sliding of the electrolyzer's exit chute. That's basically a close-up shot of the exit chute of a single electrolyzer, of which there are 6 in a complete module.
The important thing is this is a new phenomenon and we've never seen this before. And we started to notice it over the summer of last year. And essentially after a period of operation, the lead would simply stop sliding off the exit chute. And to put this in perspective many times earlier we have the opposite problem, well, not really a problem. So we've never seen lead not slide of the exit chute. So what caused it? What we discovered after quite a lot of investigation was that the electrolyte was stratifying in the plating tanks. So we have 6 electrolyzers in a module. Each electrolyzer has a plating tank, and each plating tank that has the anodes and cathodes in it, from which we plate a lead on to the cathode from the electrolyte that contains a lead. And stratification means that we have zones within the tank in which the electrolyte is too dilute, and zones within the tank in which the electrolyte is too concentrated. That's known technically a stratification.
And it's a -- and so a phenomena is well known in the world of electrochemistry and metal plating. I think it normally occurs in seconds and minutes, not hours. And unfortunately, some of the very important benefits of our process may dilute cause of stratification quite difficult to trace. As an example of that, the electrolyte entering and exiting the system remained in specification as did the lead we produce. So that in a very simple way is sticky lead and what caused it. And the challenge there was that the process is designed to be continuous and semiautomatic or fully automatic. And it's got lead hanging up on the exit chute. To be able to run that way, we would have had to increase the amount of labor and intervention to get the lead off the chute in a periodic manner and we chose -- we decided that was not really what we wanted to do. So sticky lead is a fix. So how did we fix it? It really came down to better electrolyte mixing within the electrolyzers. And the way we did that was by increasing the headers or the manifolds that supply new electrolyte to the tanks from 1 to 2 and make some other design changes within those headers as well. We increased the electrolyte circulation rate. And together, that gave us far better control of the plating conditions. Now on top of that, we reengineered what we called the scraper table, it's something like the smelter. There's misnomer[indiscernible] in there. The table doesn't physically scrape the lead and it is, in fact, the exit chute. And one of the modifications we made is to add a programmable tool mechanism to that table, which is instantly Christian [indiscernible] the dump truck by the technical guys. And that allows us to get the lead off of on a regular basis.
So together, these 2 features allowed us to produce lead using less energy, that's the key point. And so over this summer, when we discovered this problem, we were faced with a choice, do a workaround. We quickly figured out a couple of ways of getting the lead off the table. But the thing that I was concerned about was we didn't really know why we had a problem. And what I believed then and what we've proven is that, if you figure out the root cause to a technical problem, there is often an opportunity to improve that process. And essentially that's exactly what happened. So when we add the fixtures to the sticky lead problem, that's actually allowed us to produce lead now using less energy, and we made an announcement about that recently. And essentially, we now are producing lead at the target rate of production, 13% to 14% less energy usage. And we think that gives us longer-term potential to increase throughput.
So that's sticky lead. What I'm going to talk about now is the -- how we go about retrofitting that and ramping our production of AquaRefined lead? So what we've developed is what we call a fix kit. It's a kit of parts that goes on to the existing AquaRefining modules. With that developed, validated in and in regular use. We're now totally focused on retrofitting all of our AquaRefining modules with this fixed kit. And the fixed kit itself consists of new electrolyte manifolds, basically pipe and modified exit chutes with the pneumatic tilt feature. All of the key parts for the 16 fix kits are now on site and retrofitting of all of those 16 modules has commenced. And one of the things that's important to note is that we planned the retrofit of the fixed kits. We planned that campaign, not as a campaign, not a rollout. This isn't Orange County choppers with people jumping on one thing at a time. It's actually planned as 16 modules that have been disassembled, ready to accept the kit of parts and then with teams of people who have been trained up to do a specific task in the retrofit. So we're now entering a very intensive phase over the next 3 weeks, as we take the modules that are being prepared to accept the fixed kits and we actually have them in.
So the 16 modules are organized in what we call 2 trains of 8 modules. Each of the -- so the 8 modules in 2 lines or 16 modules in 2 lines of 8. We call those trains. Each train of modules has a group -- 2 groups of 4 modules. And moving forward, our goal is to have all of the fixed kit applied by the end of March and to have initial runs on the first group of 4 modules in play before the end of March, and then ramp up the rest of the AquaRefining facility and start producing quantities of AquaRefined lead during quarter 2.
And that covers the retrofit of the components to the modules that we already had on site and then how we ramp up production in that site. And the real key here is to get the fixed kit applied by the end of this month, have 1 of the group of 4 modules operating by the end of this month, bring the rest of the modules online and then move progressively from daytime operation to longer periods of operation to 24-hour operation, as we move through the quarter 2.
So now I'm going to talk a little bit more about the overall ramp-up of the operations in the facility. And just really want to pick up on some key themes here. And the first thing is that we made some more major changes during 2017. We changed the management. We changed supervisors. We brought a new plant management process engineering, environmental health and safety and maintenance. And we moved the technology -- the leadership of the technology and engineering group to trig [indiscernible] during 2017. And basically brought all of the engineering and science team from Alameda up to Reno and located all of our activities here. And we're now really seeing the benefits of that. There is a time delay in implementing changes and sweeping is the ones that we made, and we're now seeing the benefits of those multiple organizational staffing and equipment changes that we did -- we talked about during 2017, and we're now seeing the benefits of that. So in essence, where we're at now is we reported earlier last year challenges in our breaking and separation, well that's now working. The desulfurization and digestion processes, which is essentially electrolyte production, led there in operation and ramping up the throughput to meet the needs of AquaRefining. And one of the key themes here is that we're really running the facility to feed the AquaRefining modules. We've proven at the break, it works, we've proven that desulfurization works. We've got everything in place. So we're really ramping things up to feed the AquaRefining modules as we bring them online.
And essentially, the overall thing here is that we're now starting to function as an operating facility. I'll talk a little bit about how we actually plan to ramp up our lead products is -- there's a number of different ways you can do that. And essentially, what we've got in place right now is 2 50-tonne lead kettles. We've got an additional 4 kettles in place, but not fully built out and that to be added as we need them.
We've had operators of ours work with JCI, we've got a tremendous amount of help and commitment from JCI by providing assistance with both operator training at their facilities and then we follow up training of those guys in our own facilities. And that's been a tremendous help towards the -- helps de-risk ramp up and it has the potential to accelerate supplier approval, our approval as a supplier of high-purity lead. But it also gives JCI some insights and helping how we go about planning together the retrofit of JCI's facility. So that's the backdrop to what we're doing on preparing to ramp up their products. The important point to note is that the product progression. So basically, we're going to start by making lead bullion. Lead bullion is a commodity grade of lead. It's -- if you look at any metals or materials company, it's routine to start off by producing the high volume, lowest risk version of their product. And in the lead world, that's bullion. So we're starting with that and the AquaRefined lead that we've made, and we'll continue to make and the lead that we call direct to kettle, that's the lead that's harvested directly out of the batteries, it's soft lead and the grid lead, all of that is combined into a standardized lead product called bullion. And then we plan to progress directly to the high-purity grades of AquaRefined lead, and we need to build up the production of the AquaRefining modules to get the production rate sufficient that we can bring a dedicated lead kettle online that we will fill with high-purity lead and used to produce high-purity lead. And then, last, we're going to progress to specific alloys that meet JCI's specification. And in this sequence, there is a slight change. We had initially thought we would start with bullion, then we progressed to lead alloys, and then finally, moved to high-purity grade. We've actually brought forward the plan to progression to the high-purity grades of AquaRefined lead and we're pretty pleased that we were able to do that.
So moving on. Let's talk a little bit about intellectual property. The important point here is that our first key patent has been allowed in the U.S. and 5 other countries. Our first patent is main devices and methods, the smelters recycling. It's absolutely key. It's been allowed in the U.S., Canada, Korea, Japan, Australia and South Africa. Many other countries are in play. We just got some encouraging notifications from China and several other countries. The important thing is that, that first patent was allowed with substantially all of our claims intact. I mean, to say so, pretty significant prior ops in the field of electrochemical plating of lead. And we believe that, that has generated -- first of all, it's a significant achievement and there is quite a significant amount of skepticism about whether we would be able to achieve that earlier last year and we have. And this achievement establishes a very important precedent on priority, [ prior our ], patentability. And we'd, obviously, not going to stop there. We've got 7 additional patent families filed and pending. And we are -- actually have been filing next-generation filings, and that started with some provisional and the one U.S. filings. And we're pretty pleased. There was a lot of hard work both from the technical and the legal teams in prevailing with our first patent. So it's established a phenomenal precedent and we're all pretty pleased, and I'm tremendously proud of the team for achieving that.
So with that said, I'm now going to hand over to Tom Murphy, who will take us through the summary of the financials in this quarter and the year-end.