EV1’s Chilalo Graphite Proves Durable for Fuel Cell Separator Plates

Chilalo Graphite’s Unique Flake Profile Unlocks New Markets

Evolution Energy Minerals (ASX:EV1) has spotlighted a compelling new use for its Chilalo coarse flake graphite beyond battery anodes: fuel cell separator plates. The company’s test work, conducted in the United States, shows that 58% of the Chilalo resource’s graphite occurs as coarse flakes, with a substantial portion exceeding +50 mesh size. These flakes are not only large but unusually thick and exhibit low halogen content, ticking the boxes for durability and purity demanded by fuel cell manufacturers.

American Energy Technologies Company (AETC), EV1’s US technology partner, identified the graphite’s flake size and thickness as key factors providing exceptional oxidation resistance, withstanding temperatures up to 900°C. This is significant given that proton exchange membrane (PEM) fuel cells typically operate around 70-80°C, suggesting Chilalo graphite separator plates could offer a robust tenfold safety margin in thermal stability.

Fuel Cell Applications Span Data Centres to Electric Vehicles

Fuel cells are gaining traction in diverse sectors including advanced transportation, backup power, and defence. Notably, data centres in the US are adopting fuel cell power, with a 1 MW installation approved by the Department of Energy in 2024 involving Microsoft, Caterpillar, and Ballard Power. Ballard alone has installed 10 MW of fuel cell power since 2025, with an additional 15 MW underway.

EV1 sees a strategic opportunity in Japan’s PEM-type fuel cell electric vehicle market, where coarse flake graphite concentrate is a required input. Chilalo’s location near East Tanzanian ports offers a logistical advantage for direct supply into Tokyo, a hub for fuel cell vehicle manufacturing. The graphite concentrate from Chilalo’s planned concentrator is expected to deliver 95–97 wt.% carbon, aligning with market requirements.

Product Qualification and Industry Context

AETC’s analysis confirms Chilalo graphite’s low halogen levels, fluorine below 10 ppm and chlorine between 50–70 ppm, further enhancing its suitability for fuel cell components. The company’s recent production of 280 kg of 99.99% carbon graphite concentrate under the EU-funded STREAMS programme complements these findings, underscoring the deposit’s versatility across battery and fuel cell markets.

While industry players like Ballard highlight graphite bipolar plates’ durability and power density advantages, EV1 stresses that these developments illustrate market potential rather than existing customer contracts. The company is focused on converting Chilalo’s natural graphite qualities into commercially viable products, targeting first concentrate production in October 2027, subject to funding and approvals.

Managing Director Highlights Value Beyond Batteries

Craig Moulton, EV1’s Managing Director, emphasised that unlocking the value of Chilalo’s coarse flakes is central to the project’s economics. He noted, “Data-centre power and hydrogen transport offer compelling markets alongside our battery-materials programme.” The company’s staged development approach aims to capitalise on these natural advantages by delivering products that meet customer needs.