Evolution Energy Minerals Confirms Chilalo Graphite Meets Fuel Cell Quality Bar
Key Takeaways
- AETC test work confirms Chilalo graphite meets all four critical physical and chemical requirements for PEM fuel-cell separator plates, including fluorine below 10 ppm and chlorine at 50–70 ppm across the three coarsest size fractions.
- The fuel-cell separator plate market accepts 95–97 wt.% carbon, meaning Chilalo can serve this end market directly from its planned concentrator without the additional purification step required for battery-anode graphite.
- 58.0% of the DFS concentrate mix is +80 mesh and coarser, with +80 mesh flakes measured at 50–75 µm thick by SEM — the coarse, thick-flake profile that drives oxidation resistance and separator plate durability.
- Japan is identified as a named target market, with Chilalo's east Tanzanian port position providing a direct logistics pathway to Tokyo, where PEM fuel-cell vehicle components are manufactured.
- EV1 is targeting first graphite concentrate production in October 2027, subject to funding and approvals, with no customer offtake commitments in place at this stage.
Chilalo graphite clears the bar for fuel-cell separator plate applications
Evolution Energy Minerals (ASX: EV1) has released test-work results confirming that coarse flake graphite from its Chilalo deposit in Tanzania meets the physical and chemical requirements for graphite separator plates used in low-temperature fuel cells. The results, reported as Exploration Results under ASX Listing Rule 5.7, point to two emerging end markets: data-centre power supply and fuel-cell electric vehicles (FCEVs).
The test work was conducted by American Energy Technologies Company (AETC) of Wheeling, Illinois, EV1’s US graphite technology partner. AETC’s assessment draws on concentrate produced from the Chilalo deposit and characterised across multiple size fractions.
Underpinning the opportunity is Chilalo’s coarse-flake resource profile, established in the March 2023 Definitive Feasibility Study (DFS): 58.0% of the DFS concentrate mix is +80 mesh and coarser, including 31.1% at +50 mesh and coarser. The planned Chilalo concentrator is expected to produce a 95–97 wt.% carbon concentrate grade.
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What the test work actually found
AETC identified three physical and chemical attributes as critical for fuel-cell separator plate manufacturing: large flake size, thick graphite particles, and low halogen content. Chilalo’s material performed well across all three.
Halogen measurements on the three coarsest size fractions recorded fluorine below 10 ppm and chlorine of 50–70 ppm. Scanning electron microscopy (SEM) measured +80 mesh flakes at approximately 50–75 µm thick. These characteristics directly influence separator plate durability: thick flakes provide enhanced oxidation resistance, and low halogen content is a strict requirement for fuel-cell separator plates.
On oxidation resistance, the source material’s threshold is an order of magnitude above the average PEM fuel-cell operating temperature of 70–80°C, providing a substantial safety margin for separator plates manufactured from Chilalo graphite. Importantly, AETC’s assessment identifies the 95–97 wt.% carbon concentrate-grade feedstock as suitable for the fuel-cell market directly from the planned concentrator. Unlike battery-anode graphite, which requires further purification, this application does not require an additional purification step.
Craig Moulton, Managing Director
“Chilalo’s value extends well beyond battery anodes… identifying applications that reward the quality of those flakes is central to capturing the value of the project.”
“Data-centre power and hydrogen transport offer compelling markets to pursue alongside our battery-materials programme.”
Emily Schmidt, Business Development and Project Manager, AETC
“The fact that Chilalo flake is not only coarse but also contains very thick particles provides an additional benefit that leads to greatly enhanced oxidation resistance… That, in turn, facilitates the durability of fuel cell products that use these flakes in the construction of fuel cells.”
Understanding fuel-cell graphite — why flake quality is the gating factor
A graphite separator plate is a moulded component inside a PEM fuel cell. It is a solid plate with engineered channels that separates the anode from the cathode and manages the flow of gases and liquids. The material quality of the plate directly determines how long the fuel cell lasts under operating conditions.
Four attributes define suitability for this application, as identified by AETC:
- Coarse flake size
- Increased particle thickness
- Oxidation resistance
- Low halogen content (fluorine below 10 ppm, chlorine 50–70 ppm)
The concentrate-grade threshold matters for project economics. Battery-anode graphite requires purification, adding cost and processing complexity. The fuel-cell separator plate market accepts 95–97 wt.% carbon, meaning Chilalo can serve this end market with material from the concentrator plant planned for the mine site, without a purification stage.
| Attribute | Chilalo Result | Why It Matters for Fuel Cells |
|---|---|---|
| Flake size | 58.0% of DFS mix at +80 mesh and coarser | Coarse flakes provide structural integrity in moulded separator plates |
| Particle thickness | +80 mesh flakes approx. 50–75 µm (SEM) | Thicker particles resist oxidation at operating temperatures, extending component life |
| Oxidation resistance | Threshold an order of magnitude above PEM operating temp of 70–80°C | Greater safety margin means more durable separator plates across the product’s service life |
| Halogen content | Fluorine <10 ppm; Chlorine 50–70 ppm | Low halogens protect the PEM membrane from chemical degradation |
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Market context and what’s next for EV1
Fuel cells are used across a range of applications: data-centre power, FCEV transport, back-up and uninterruptible power supply (UPS) systems, and defence. The data-centre segment is an active and growing area, with industry participants advancing megawatt-scale fuel-cell installations for power supply use cases. These industry developments illustrate the market for fuel-cell technologies; they do not represent customer relationships or offtake commitments with EV1.
Japan is specifically noted in the announcement as an attractive target market. PEM-type fuel-cell vehicles are available for sale in Japan, and the geographic position of the Chilalo resource is favourable for direct supply of coarse flake concentrate from east Tanzanian ports to Tokyo, where PEM fuel-cell components for vehicles are manufactured.
The fuel-cell pathway complements, rather than competes with, EV1’s battery-materials work. On 30 July 2026, EV1 announced that AETC had produced 280 kg of Chilalo graphite purified to 99.99 wt.% carbon from concentrate supplied at 95.7% TGC, within the EU-funded STREAMS programme. That result demonstrates Chilalo material can serve the battery-anode market with additional purification; the fuel-cell results show the same resource base can serve a separate high-value market at concentrate grade.
EV1 is targeting first graphite concentrate production in October 2027, subject to funding, approvals, and execution risks. No further test work is currently planned on the 2019 concentrate samples, though AETC has indicated interest in further separator plate and value-added market work. The company’s stated objective is to position Chilalo across multiple end markets, battery anodes and fuel cells, to maximise value from its coarse-flake resource.
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