Recent
Developments Related to Liquidity and Capital Resources
We have
incurred significant net losses since inception and we have relied on our
ability to fund our operations principally through both registered and
unregistered offerings of our securities and prepayments on our long-term
polysilicon contracts. Even if we are successful in securing additional
long-term polysilicon contracts that could provide additional prepayments, and
our existing customers fulfill their obligations to make additional prepayments
when due (of which there can be no assurances), we will still need to seek
additional financing to complete our polysilicon production facility
currently under construction. As of March 31, 2009, we had cash and cash
equivalents on hand of $17.4 million and short term liabilities of $40.0
million. Consequently, there is substantial doubt that we will have
sufficient cash to meet all of our obligations as they come due over the next
twelve months. We do not expect to generate significant revenue until we
successfully commence the manufacture and shipment of polysilicon and begin
meeting the obligations under our supply contracts. Furthermore, assuming the
total cost of construction and equipment does not exceed $390 million, that all
of our existing polysilicon customers make timely prepayments in full and that
we are able to secure additional prepayments from new polysilicon customers, we
believe we will still need to raise an amount between $35 and $55 million to
complete the construction of our 4,000 metric ton plant. If we are unable to
secure additional long-term supply contracts and prepayments, assuming the cost
to construct and equip the plant is $390 million and that all of our existing
customers make their prepayments when due, the amount we will need to raise
could be as much as $106 million. If we are unable to secure additional
long-term supply contracts and prepayments, if one or more of our polysilicon
supply customers fail to meet their obligations to make timely prepayments
and/or if the actual cost to complete the plant is more than $390 million, the
amount we will need to raise could exceed $106 million. We previously
intended to finance the construction of our polysilicon production facility
through project financing; however, as of May 2009, we believe we will need to
raise additional capital through other means for the procurement and
construction of our polysilicon manufacturing facility.
Our
ability to continue as a going concern depends on our ability to raise equity or
debt capital, increase revenues and reduce expenses. We have already modified
payment terms in purchase orders with more than twenty of our vendors to
structure payment plans for amounts past due and to be invoiced in the future.
Our management continues to evaluate a variety of alternatives to raise capital
and manage our liquidity. These alternatives include, without
limitation:
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debt
financing, including financing that is guaranteed by a private third
party;
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one
or more or equity offerings, including an offering of stock the Company
previously registered with the Securities and Exchange Commission on Form
S-3;
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prepayments
for product to be delivered under new long-term polysilicon supply
contracts;
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government
funding from grants and/or loan
guarantees;
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further
extending the construction schedule and payment plans with vendors;
and/or
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consummating
a transaction, which could result in a change of
control.
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There are
no assurances that we will be successful in executing any of the foregoing
alternatives. If we are unable to raise capital and manage our liquidity, there
is substantial doubt that we will be able to continue as a going concern through
at least March 31, 2010. The inability to continue as a going concern could
result in an orderly wind-down or other potential forms of restructuring. The
amount and timing of our future capital needs depend on many factors, including
the timing of our development efforts, opportunities for strategic transactions,
and the amount and timing of any revenues we are able to generate. Given our
current business strategy, however, we will need to secure additional financing
in order to execute our plans and continue our operations.
Hoku
Materials
In
February 2007, we incorporated Hoku Materials to manufacture polysilicon, a key
material used in PV modules. We had originally planned to use the polysilicon
internally by Hoku Solar to manufacture our own brand of solar modules, and for
sale to the larger solar market. However, as a result of the
polysilicon supply shortages and strong demand from third-party customers that
existed in recent calendar years, and our revised strategy for Hoku Solar, we
revised our plan for Hoku Materials to sell all of our planned output of
polysilicon to third-party customers.
In May
2007, we commenced construction of our planned polysilicon manufacturing
facility in Pocatello, Idaho
.
We had originally planned the annual capacity of the polysilicon
manufacturing facility to be 3,500 metric tons per year and for construction and
equipment to cost approximately $400 million. In April 2008, we issued a change
order with Stone & Webster, Inc., our engineering and procurement services
provider and, as a result, revised our estimate of the total actual cost to
construct and equip our polysilicon facility downward from $400 million to $390
million. This estimate is based on our discussion with vendors, declining costs
of materials and labor and ongoing adjustments of certain design elements;
however, changes in costs, modifications in construction timelines and other
factors could cause the actual cost to significantly exceed our
estimate.
In
September 2008, we announced that we would be increasing our planned polysilicon
facility capacity from 3,500 metric tons per year to 4,000 metric tons per year.
We do not believe that this increase in capacity and related modifications to
the production facility will require a significant amount of additional capital,
if any; however, we are continuing to review the $390 million estimated actual
cost to complete the facility. In January 2009, we received six polysilicon
reactors at our Pocatello facility and all six reactors have been assembled and
put into place on our production floor. The reactors, which were manufactured in
Germany by GEC/MSA, are the first units to arrive in Pocatello out of a planned
total order of 28. The next shipment of 10 polysilicon reactors and related
equipment is scheduled to arrive at our facility no later than the third quarter
of calendar year 2009.
We had
originally planned for our first commercial shipment of polysilicon to occur in
the first half of calendar year 2009. However, due to the effect of certain
delayed customer prepayments, this schedule has been adjusted and we now expect
our first commercial shipment to occur in the second half of calendar year 2009.
We intend to ramp-up production throughout the second half of calendar year
2009, and into calendar year 2010, when we expect to reach full production
capability. We expect this revised schedule will still allow us to meet all
delivery obligations to our current customers; however, there are no assurances
that we will not need to revise this schedule further.
Once our
plant is operating at full capacity, we expect that we will be able to meet the
annual delivery requirements in our seven existing long-term polysilicon supply
contracts. In addition, as of May 15, 2009, we have approximately 600 to 800
metric tons of unallocated annual polysilicon production capacity from our
planned production output of 4,000 metric tons per year, which either may be
sold under one or more new long-term contracts, reserved for strategic purposes,
or sold on the spot market.
As of
March 31, 2009, we had received a total of $134 million in customer prepayments.
In April 2009, we received a $7 million prepayment from Wealthy Rise
International, Ltd., and in May 2009, we received an additional $14.5 million
from Tianwei New Energy (Chengdu) Wafer Co., bringing the total customer
prepayments to $155.5 million. As of May 15, 2009, all of our customers were
current on their prepayment obligations. However, during fiscal 2009 certain
customer prepayments were less than we anticipated and/or received later than
originally expected. To manage the potential effects of such delays, we are
deferring approximately $40 million in capital expenditures by delaying
construction of our on-site trichlorosilane, or TCS, production facility. We are
in discussions with third-party TCS producers for a TCS supply contract to
enable us to execute on this strategy. The procurement of third-party TCS would
result in an increase in our near-term cost of goods sold.
We
previously intended to finance the construction of our polysilicon production
facility through project financing; however, as of May 2009, we believe we will
need to raise additional capital through other means for the procurement and
construction of our polysilicon manufacturing facility. We continue
to evaluate a variety of alternatives to finance the construction of our
polysilicon production facility. These alternatives include one or more debt or
equity offerings, government funding from grants, loan guarantees or other
transactions, a consequence of which could include the sale or issuance of stock
to third parties and/or a change of control. Assuming the total
actual cost to complete the construction of our 4,000 metric ton plant is $390
million, that our existing polysilicon customers make their prepayments in full
when due and that we are able to secure additional prepayments from new
polysilicon customers, the amount of debt and/or equity we believe we will need
to raise could range between $35 and $55 million. If we are unable to secure one
or more additional long-term supply contracts and customer prepayments, the
amount we will need to raise could be as much as $106 million. If we are unable
to secure additional prepayments under new polysilicon supply contracts, if one
or more of our customers fail to meet their obligations to make timely
prepayments, and/or if the cost to complete the plant is $390 million, the
amount we will need to raise could exceed $106 million. If we are unable to
secure adequate debt or equity financing to complete construction of our
polysilicon production facility in time to meet certain milestones and/or to
meet our customer commitments, our business will be materially harmed and we may
be forced to delay, alter or abandon our planned business operations. If we must
raise capital through one or more equity offerings, depending on the size of the
offering, the issuance of our stock could result in material impairment to our
existing stockholders’ voting power, material impairment to our existing
stockholders’ share value and/or a change of control. There are no assurances
that we will be able to secure any additional debt or equity financing on
favorable terms, at the time such financing is needed, or at all.
Hoku Solar
In March
2007, we incorporated Hoku Solar to assemble and install our own brand of PV
modules. In June 2007, we announced a change in our strategy, which is to focus
on the sale of turnkey PV system installations, and related services, and not to
enter the solar-module manufacturing business. In connection with this revised
strategy, we resold our solar module manufacturing equipment in July 2007,
before it was delivered to us, and resold our inventory of solar
cells.
We
continue to design, engineer and install turnkey PV systems and use modules
purchased from third-party suppliers, which we believe we can purchase at lower
cost than the cost at which we could manufacture our own brand of modules. In
December 2008, due to our decision not to enter the solar-module manufacturing
business, along with decreased activity in our fuel cell business, we sold our
real property and improvements, including our corporate headquarters, located in
Kapolei, Hawaii.
Under the
name Hoku Fuel Cells, we operate our fuel cell business, which has designed,
developed and manufactured membranes and membrane electrode assemblies, or MEAs,
for proton exchange membrane, or PEM, fuel cells. Hoku MEAs are designed for the
residential primary power, commercial back-up, and automotive hydrogen fuel cell
markets. To date, none of our customers have commercially deployed products
incorporating Hoku MEAs or Hoku Membranes, and we have not sold any products
commercially. In August 2007, we completed our most recent material fuel cell
contract with the U.S. Navy.
We intend
to selectively pursue patent applications in order to protect our technology,
inventions and improvements related to our fuel cell products; however, we do
not currently plan on actively pursuing any new contracts or committing material
resources to further develop our fuel cell products.
Our
Solar Businesses
Solar
Industry Overview
Solar
Power Systems
Solar
power systems convert sunlight directly into electricity. These systems are used
for “on-grid” and “off-grid” residential, commercial and industrial
applications, and for a variety of consumer applications. “On-grid” markets
refer to applications where solar power is used to supplement a customer’s
electricity purchased from the utility network, whereas “off-grid” markets
include those applications where access to utility networks is not economical or
physically feasible, including road signs, highway call boxes and communications
support along remote pipelines and telecommunications equipment, as well as
rural residential applications. Consumer applications include garden lights,
other outdoor lighting and handheld devices such as calculators.
A solar
power system consists of one or more PV modules electrically connected in
series, and typically includes a power inverter to convert the direct current,
or DC, electricity produced by the modules into alternative current, or AC,
electricity that is required for most applications. For “on-grid” applications,
an interconnect to the utility grid is required, and in “off-grid” applications,
a battery may be required to provide power at night, and at other times when the
sun is not providing enough solar radiation for the solar power system to
generate sufficient electricity to power the electrical load. The key components
of PV modules are PV cells, which are in turn made from silicon wafers. Silicon
wafers are made from silicon ingots, which are in turn made from raw
polysilicon. Following is a brief overview of these products and
technologies.
Polysilicon
Polysilicon
is an essential raw material in the production of PV cells. Polysilicon is
created by refining quartz or sand to produce electronic-grade or solar-grade
polysilicon. The key difference between electronic-grade and solar grade
polysilicon is the purity requirement. The purity requirement for solar-grade
polysilicon is typically 99.9999%-99.999999% pure, while electronic grade
polysilicon tends to be at least 99.9999999% pure. The majority of polysilicon
production begins with quartz or sand, which is refined into metallurgical grade
silicon, or MG-Si. MG-Si is then purified by various chemical processes. There
are two main methods in which this can be accomplished, namely silane-based and
trichlorosilane (TCS)-based processes. There are two technologies for producing
polysilicon from silane and TCS: the Siemens reactor method and the fluidized
bed reactor, or FBR method. In the Siemens reactor process, the silane or TCS
gas is introduced into a thermal decomposition furnace (reactor) with high
temperature polysilicon rods inside a jacketed bell jar. The silicon contained
in the gas will deposit on the heated rods, which gradually grow until the
desired diameter has been reached. In the FBR process, silane or TCS gas is
introduced into a tube-like reactor in which small polysilicon granules are
suspended in the gas stream, referred to as the fluidized bed. The silicon
contained in the gas deposits on the surface of the hot granules in the bed
until the desired diameter has been reached. The end product is in the form of
rods or chunks of polysilicon. The technology in the Siemens reactor was
developed in the late 1950’s, is widely implemented, accounting for a majority
of the polysilicon production today, and currently produces a higher purity of
material.
Silicon
Ingots and Wafers
PV
Cells
PV cells
are made from silicon wafers. The wafer undergoes a process to combine positive
and negative layers on the wafer, attach electrodes, and coat with
anti-reflective materials. The performance of a PV cell is measured by its solar
radiation conversion efficiency. The solar radiation conversion efficiency is a
measure of the net percentage of energy from solar radiation that the PV cell
converts into electricity. PV cells made from multicrystalline wafers may have
efficiencies in the range of 13-18%, whereas PV cells made from monocrystalline
wafers typically have higher efficiencies in the range of 20%, but are more
expensive to produce.
PV
Modules
PV
modules are commonly known as solar panels. A PV module is made by electrically
wiring together PV cells in series to increase the total voltage output. The
connected cells are laminated in a glass or plastic covering and then framed.
The wires connecting the PV cells terminate in a junction box to allow multiple
PV modules to be electrically connected in series to further increase the
voltage and power output.
Hoku
Materials
Business
Strategy and Planned Polysilicon Product
Our goal
is to be a leading provider of polysilicon. We plan to manufacture solar-grade
polysilicon using TCS in a Siemens reactor. We believe it is the most proven
process with the least technical risk.
Current
Customers
During
fiscal 2009, we added four new long-term supply contracts and also amended four
long-term polysilicon supply contracts, some of which were entered into earlier
in fiscal 2009. We also terminated two contracts during fiscal 2009. As of March
31, 2009, we have contracted future revenue with six leading solar companies for
the sale of up to approximately $1.9 billion of polysilicon over a ten-year
period, subject to meeting certain milestones and other conditions.
Once our planned facility,
which is being designed to produce up to 4,000 metric tons of polysilicon per
year, is operating at full capacity, we expect that we will be able to meet the
annual delivery requirements in our seven existing polysilicon sales contracts
with our six existing long-term customers (we have two separate supply contracts
with one of our customers). In addition, we have approximately 600 to 800 metric
tons of unallocated annual polysilicon production capacity from our planned
production output of 4,000 metric tons per year, which may be sold under one or
more new long-term contracts, reserved for strategic purposes, or sold on the
spot market. If such polysilicon is sold under one or more long-term contracts,
such sales may provide additional prepayments that could possibly reduce the
amount of additional financing needed to complete construction of our
plant.
Wuxi Suntech Power Co. Ltd.
In June 2007, we entered into a fixed price, fixed volume polysilicon supply
agreement, or the Suntech Supply Agreement, with Wuxi Suntech Power Co., Ltd.,
or Suntech, to provide Suntech with up to approximately $678 million of
polysilicon sales over either a seven or a ten-year period.
In May
2008, we amended and restated the Suntech Supply Agreement, or the Amended
Suntech Supply Agreement, whereby approximately $678 million may be payable by
Suntech to us during a definite ten-year period, subject to achieving certain
milestones, the acceptance of product deliveries and other conditions.
Additional amounts may be payable for polysilicon products shipped in 2009.
Suntech has paid us a cash deposit of $2 million as prepayment for future
product deliveries and is obligated to pay an additional $45 million in three
equal installments based on the achievement of certain milestones within
specified timeframes, including the completion of a test demonstration of at
least two polysilicon reactors, completion of a test demonstration of our TCS
production facility, and the shipment of specified quantities of
polysilicon.
The term
of the Amended Suntech Supply Agreement is ten years from the date of the first
shipment. Each party, however, may terminate the Amended Suntech Supply
Agreement at an earlier date under certain circumstances, including, but not
limited to, the bankruptcy, assignment for the benefit of creditors, liquidation
or a material breach of the Amended Suntech Supply Agreement by the other party.
Suntech may terminate the Amended Suntech Supply Agreement if we fail to meet
certain milestones in 2009 related to our polysilicon production facility
presently under construction. Upon Suntech’s termination of the Amended Suntech
Supply Agreement, we are generally required to refund to Suntech all of the
prepayments made as of the date of termination, which was $2 million as of March
31, 2009, less any part thereof that has been applied to the purchase price of
polysilicon delivered under the Amended Suntech Supply Agreement.
Pursuant
to the Amended Suntech Supply Agreement, we granted to Suntech a security
interest in all of our tangible and intangible assets related to our polysilicon
business to serve as collateral for our obligation to repay the remaining amount
of all prepayments made by Suntech that has not been applied to the purchase
price of polysilicon delivered as of the date of such termination should Suntech
elect to terminate the contract under certain circumstances. Such security
interest is subordinated to any third-party debt secured to finance construction
of the polysilicon production facility and pari passu with security interests
granted to each of our other long-term polysilicon supply customers. The
security interest will continue until all prepayments have been credited against
the shipment of product, and only with respect to the amount of prepayment that
has not been so credited.
If the
Amended Suntech Supply Agreement is terminated for any reason, our business will
be materially harmed and we will need to secure new funds in order to finance
the construction of our polysilicon production plant. Securing new funds may
delay the anticipated timing of completion of the production plant, which delay
may result in us failing to meet our delivery requirements under our other
supply agreements. We may not be able to secure new funds on terms as favorable
to us as those under the agreement with Suntech or at all. If we are unable to
secure new funds, we will not be able to complete construction of the production
plant, our business will be materially harmed and we may be forced to delay,
alter or abandon our planned business operations.
Solarfun Power Hong Kong
Limited.
In November 2007, we entered into a fixed price, fixed volume
supply agreement, or the Solarfun Supply Agreement, with Solarfun Power Hong
Kong Limited, or Solarfun, a subsidiary of Solarfun Power Holdings Co., Ltd. In
January 2008, we entered into the first Amended and Restated Supply Agreement
with Solarfun. In May 2008, we entered into a Second Amended and
Restated Supply Agreement, or the Second Solarfun Supply Agreement with
Solarfun. In October 2008, we entered into Amendment No. 1 to the Second
Solarfun Supply Agreement. In March 2009, we entered into Amendment No. 2 to the
Second Solarfun Supply Agreement, or Solarfun Amendment No. 2. Pursuant to
Solarfun Amendment No. 2, Solarfun agreed to purchase from us specified
quantities of polysilicon over a ten-year period, during which up to
approximately $384 million may be payable to us. Under Solarfun Amendment No. 2,
we are obligated to commence shipments of polysilicon in March 2010. As of March
31, 2009, Solarfun had paid to us cash deposits of $37 million as prepayment for
future polysilicon product deliveries. Under Solarfun Amendment No. 2, Solarfun
must also make an additional prepayment of $18 million in installments. The
first installment of $5 million was paid in March 2009. The second installment
of $8 million is payable in July 2009. The remaining $5 million is to be paid in
increments of $1 million in each of August and September 2009, and $3 million in
October 2009. The final prepayment of $5 million is payable in January
2010.
The term
of the Second Solarfun Supply Agreement, as amended, or the Amended Solarfun
Supply Agreement, is ten years from the date of the first shipment. Each party,
however, may terminate the Amended Solarfun Supply Agreement at an earlier date
under certain circumstances, including, but not limited to, the bankruptcy,
assignment for the benefit of creditors, liquidation or a material breach of the
Amended Solarfun Supply Agreement by the other party. Our failure to commence
shipments of polysilicon by June 2010 constitutes a material breach by us under
the terms of the Amended Solarfun Supply Agreement, among other circumstances.
Solarfun’s failure to pay any part of the remaining $18 million in cash deposits
when due constitutes a material breach of the contract by Solarfun, among other
circumstances. Upon Solarfun’s termination of the Amended Solarfun Supply
Agreement under certain circumstances, we are required to refund to Solarfun all
of the prepayments made as of such termination, which was $37 million as of
March 31, 2009, less any part thereof that has been applied to the purchase
price of polysilicon delivered under the Amended Solarfun Supply Agreement. Upon
a termination of the Amended Solarfun Supply Agreement by us, we generally may
retain the entire amount of prepayments made as of the date of termination as
liquidated damages, less any part thereof that has been applied to the purchase
price of polysilicon delivered under the Amended Solarfun Supply
Agreement.
Pursuant
to the Amended Solarfun Supply Agreement, we granted to Solarfun a security
interest in all of our tangible and intangible assets related to our polysilicon
business to serve as collateral for our obligation to repay the remaining amount
of all prepayments made by Solarfun that has not been applied to the purchase
price of polysilicon delivered as of the date of such termination, should
Solarfun elect to terminate the contract under certain circumstances. Such
security interest is subordinated to any third-party debt we may secure to
finance construction of our polysilicon production facility and pari passu with
security interests granted to each of our other long-term polysilicon supply
customers. The security interest will continue until all prepayments have been
credited against the shipment of product, and only with respect to the amount of
prepayment that has not been so credited.
If the
Amended Solarfun Supply Agreement is terminated for any reason, our business
will be materially harmed and we will need to secure new funds in order to
finance the construction of our polysilicon production plant. Securing new funds
may delay the anticipated timing of completion of the production plant, which
delay may result in us failing to meet our delivery requirements under our other
supply agreements. We may not be able to secure new funds on terms as favorable
to us as those under the agreement with Solarfun, or at all. If we are unable to
secure new funds, we will not be able to complete construction of the production
plant, our business will be materially harmed and we may be forced to delay,
alter or abandon our planned business operations.
Jiangxi Jinko Solar Co., Ltd.
In July 2008, we entered into a fixed price, fixed volume supply
agreement with Jiangxi Jinko Solar Co., Ltd., formerly known as Jiangxi Kinko
Energy Co., Ltd., or Jinko, for the sale and delivery of polysilicon to Jinko
over a ten-year period, or the Jinko Supply Agreement. In January 2009, we
entered into Amendment No. 1 to the Jinko Supply Agreement, or the First
Amendment. In February 2009, we entered into an Amended & Restated Supply
Agreement with Jinko, or the Amended Jinko Supply Agreement, under which the
total volume of polysilicon to be sold by us to Jinko has been reduced such that
up to approximately $119 million may be payable to us during the ten-year
period, subject to product deliveries and other conditions.
Under the
Jinko Supply Agreement, Jinko previously paid us a cash deposit of $20 million
as prepayment for future product deliveries. Under the Amended Jinko Supply
Agreement, we and Jinko acknowledged and agreed that $5 million of the $20
million previously paid to us by Jinko would be credited to the prepayment
account of Shanghai Alex New Energy Co., Ltd. See “Shanghai Alex New
Energy Co., Ltd.”, below. Jinko paid us an additional $3 million in March 2009.
Jinko is now obligated to pay an additional cash deposit of $2 million as a
prepayment for future product deliveries, which is payable in June 2009. The
Amended Jinko Supply Agreement provides that if Jinko does not provide the $2
million cash deposit when due, then we may immediately terminate the Amended
Jinko Supply Agreement and retain all previously paid cash deposits as
liquidated damages, which was $18 million as of March 31, 2009.
The term
of the Amended Jinko Supply Agreement is ten years from the date of the first
shipment. Each party, however, may terminate the Amended Jinko Supply Agreement
at an earlier date under certain circumstances, including, but not limited to,
the bankruptcy, assignment for the benefit of creditors, liquidation or a
material breach of the Amended Jinko Supply Agreement by the other party. Our
failure to commence shipments of polysilicon by December 2009 constitutes a
material breach by us under the terms of the Amended Jinko Supply Agreement,
among other circumstances. Jinko’s failure to pay the $2 million cash deposit
when due constitutes a material breach of the contract by Jinko, among other
circumstances. Upon Jinko’s termination of the Amended Jinko Supply Agreement
under certain circumstances, we are required to refund to Jinko all prepayments
made as of the date of termination, which was $18 million as of March 31, 2009,
less any part thereof that has been applied to the purchase price of polysilicon
delivered under the Amended Jinko Supply Agreement. Upon a termination of the
Amended Jinko Supply Agreement by us, we generally may retain the entire amount
of prepayments made as of the date of such termination as liquidated damages,
less any part of thereof that has been applied to the purchase price of
polysilicon delivered under the Amended Jinko Supply Agreement.
Pursuant
to the Amended Jinko Supply Agreement, we have granted to Jinko a security
interest in all of our tangible and intangible assets related to our polysilicon
business to serve as collateral for our obligation to repay the $20 million
deposit if the Amended Jinko Supply Agreement is terminated by Jinko. Such
security interest is subordinated to any third-party debt we may secure to
finance construction of our polysilicon production facility and pari passu with
security interests granted to each of our other long-term polysilicon supply
customers. The security interest will continue until all prepayments have been
credited against the shipment of product, and only with respect to the amount of
prepayment that has not been so credited.
If the
Amended Jinko Supply Agreement is terminated for any reason, our business will
be materially harmed and we will need to secure new funds in order to finance
the construction of our polysilicon production plant. Securing new funds may
delay the anticipated timing of completion of the production plant, which delay
may result in us failing to meet our delivery requirements under our other
supply agreements. We may not be able to secure new funds on terms as favorable
to us as those under the agreement with Jinko or at all. If we are unable to
secure new funds, we will not be able to complete construction of the production
plant, our business will be materially harmed and we may be forced to delay,
alter or abandon our planned business operations.
Tianwei New Energy (Chengdu) Wafer
Co., Ltd. Contract No. 1
.
In August
2008, we entered into a fixed price, fixed volume supply agreement, or Tianwei
Supply Agreement No. 1, with Tianwei New Energy (Chengdu) Wafer Co., Ltd., or
Tianwei, for the sale and delivery of polysilicon to Tianwei over a ten-year
period. Under Tianwei Supply Agreement No. 1, up to approximately $284 million
may be payable to us during the ten-year period, subject to the acceptance of
product deliveries and other conditions. In addition, we have granted Tianwei a
right of first refusal on a specified volume of production output in January and
February 2010, that is not allocated to any of our other customers, and which we
intend to sell on the spot market if Tianwei does not exercise its
option.
Under
Tianwei Supply Agreement No. 1, Tianwei paid us $42 million as a prepayment for
future product deliveries. An additional $5 million is payable when we complete
aggregate shipments of a specified volume of products to Tianwei. If Tianwei
does not pay the $5 million deposit when due, then we may immediately terminate
Tianwei Supply Agreement No. 1 and retain as liquidated damages the entire
amount of prepayments that have been paid as of the date of termination, which
was $42 million as of May 31, 2009.
The term
of Tianwei Supply Agreement No. 1 is ten years from the date of the first
shipment. Each party, however, may terminate Tianwei Supply Agreement No. 1 at
an earlier date under certain circumstances, including, but not limited to, the
bankruptcy, assignment for the benefit of creditors, liquidation or a material
breach of the contract by the other party. Our failure to commence shipments of
polysilicon by March 2010 constitutes a material breach by us under the terms of
Tianwei Supply Agreement No. 1, among other circumstances. Upon Tianwei’s
termination of Tianwei Supply Agreement No. 1 as a result of our failure to
deliver polysilicon in the amounts and by the dates required in Tianwei Supply
Agreement No. 1, we are required to refund to Tianwei 150% of the amount of
prepayments made as of the date of termination, which was $42 million as of May
31, 2009, less any part thereof that has been applied to the purchase price of
polysilicon delivered under Tianwei Supply Agreement No. 1. In most other cases,
if Tianwei terminates Tianwei Supply Agreement No. 1, then we are required to
refund to Tianwei 100% of all prepayments made as of the date of termination,
less any part thereof that has been applied to the purchase price of polysilicon
delivered under Tianwei Supply Agreement No. 1. If we terminate Tianwei Supply
Agreement No. 1 under most other circumstances, we generally may retain the
entire amount of prepayments made as of the date of termination as liquidated
damages, less any part thereof that has been applied to the purchase price of
polysilicon delivered under Tianwei Supply Agreement No. 1.
Pursuant
to Tianwei Supply Agreement No. 1, we have granted to Tianwei a security
interest in all of our tangible and intangible assets related to our polysilicon
business to serve as collateral for our obligation to repay Tianwei’s deposit if
Tianwei Supply Agreement No. 1 is terminated by Tianwei. Such security interest
is subordinated to any third-party debt we may secure to finance construction of
our polysilicon production facility and pari passu with security interests
granted to each of our other long-term polysilicon supply customers. The
security interest will continue until all prepayments have been credited against
the shipment of product, and only with respect to the amount of prepayment that
has not been so credited.
If
Tianwei Supply Agreement No. 1 is terminated for any reason, our business will
be materially harmed and we will need to secure new funds in order to finance
the construction of our polysilicon production plant. Securing new funds may
delay the anticipated timing of completion of the production plant, which delay
may result in us failing to meet our delivery requirements under our other
supply agreements. We may not be able to secure new funds on terms as favorable
to us as those under Tianwei Supply Agreement No. 1, or at all. If we are unable
to secure new funds, we will not be able to complete construction of the
production plant, our business will be materially and adversely affected and we
may be forced to delay, alter or abandon our planned business
operations.
Tianwei New Energy (Chengdu) Wafer
Co., Ltd. Contract No. 2.
In September 2008, we entered into
a second fixed price, fixed volume supply agreement, or Tianwei Supply Agreement
No. 2, with Tianwei for the sale and delivery of a predetermined volume of
polysilicon to Tianwei over a ten-year period. In addition, in October 2008, we
entered into an Amendment to Tianwei Supply Agreement No. 2 which requires us to
provide to Tianwei additional polysilicon in calendar year 2009 and calendar
year 2010. We are subject to certain price reductions in the first
year if we fail to provide these additional amounts on schedule. Under Tianwei
Supply Agreement No. 2, as amended, up to approximately $244 million may be
payable to us during the ten-year period, subject to the acceptance of product
deliveries and other conditions.
Under
Tianwei Supply Agreement No. 2, Tianwei paid us cash deposits totaling $34.5
million, as a prepayment for future product deliveries, with $10 million paid in
September 2008, and two payments of $12 million and $12.5 million in
December 2008 and May 2009, respectively. A final $2 million payment
is due when we complete aggregate shipments of a specified volume of products to
Tianwei. If Tianwei does not pay the $2 million deposit when due,
then we may immediately terminate Tianwei Supply Agreement No. 2 and retain as
liquidated damages all deposits that have been paid as of the date of
termination.
The term
of Tianwei Supply Agreement No. 2 is ten years from the date of the first
shipment. Each party, however, may terminate Tianwei Supply Agreement No. 2 at
an earlier date under certain circumstances, including, but not limited to, the
bankruptcy, assignment for the benefit of creditors, liquidation, or a material
breach of the contract by the other party. Our failure to commence shipments of
polysilicon by June 2010 constitutes a material breach by us under the terms of
Tianwei Supply Agreement No. 2, among other circumstances. Upon Tianwei’s
termination of Tianwei Supply Agreement No. 2 as a result of our failure to
deliver polysilicon in the amounts and by the dates required in Tianwei Supply
Agreement No. 2, we are required to refund to Tianwei 150% of the amount of
prepayments made as of the date of such termination, which was $34.5 million as
of May 31, 2009, less any part thereof that has been applied to the purchase
price of polysilicon delivered under Tianwei Supply Agreement No. 2. In most
other cases, if Tianwei terminates Tianwei Supply Agreement No. 2, then we are
required to refund to Tianwei 100% of the amount of prepayments made as of the
date of termination, less any part thereof that has been applied to the purchase
price of polysilicon delivered under Tianwei Supply Agreement No. 2. Tianwei’s
failure to pay any of the cash deposits when due, constitutes a material breach
of Tianwei Supply Agreement No. 2 by Tianwei, among other circumstances. If we
terminate Tianwei Supply Agreement No. 2 under most other circumstances, we
generally may retain the entire amount of prepayments made as of the date of
termination as liquidated damages, which was $34.5 million as of May 31, 2009,
less any part of thereof that has been applied to the purchase price of
polysilicon delivered under the Tianwei Supply Agreement No. 2.
Pursuant
to Tianwei Supply Agreement No. 2, we have granted to Tianwei a security
interest in all of our tangible and intangible assets related to our polysilicon
business to serve as collateral for our obligation to repay Tianwei’s deposit if
Tianwei Supply Agreement No. 2 is terminated by Tianwei. Such security interest
is subordinated to any third-party debt we may secure to finance construction of
our polysilicon production facility and pari passu with security interests
granted to each of our other long-term polysilicon supply customers. The
security interest will continue until all prepayments have been credited against
the shipment of product, and only with respect to the amount of prepayment that
has not been so credited.
If
Tianwei Supply Agreement No. 2 is terminated for any reason, our business will
be materially harmed and we will need to secure new funds in order to finance
the construction of our polysilicon production plant. Securing new funds may
delay the anticipated timing of completion of the production plant, which delay
may result in us failing to meet our delivery requirements under our other
supply agreements. We may not be able to secure new funds on terms as favorable
to us as those under Tianwei Supply Agreement No. 2 or at all. If we are unable
to secure new funds, we will not be able to complete construction of the
production plant, our business will be materially and adversely affected and we
may be forced to delay, alter or abandon our planned business
operations.
Wealthy Rise International, Ltd.
In September 2008, we entered into a fixed price, fixed volume supply
agreement, or the Solargiga Supply Agreement, with Wealthy Rise International,
Ltd., a wholly-owned subsidiary of Solargiga Energy Holdings, Ltd., or
Solargiga, for the sale and delivery of polysilicon to Solargiga over a ten-year
period, pursuant to which up to approximately $455 million would have been
payable to us during the ten-year period. Under the Solargiga Supply Agreement,
Solargiga was required to make two initial cash prepayments totaling $63 million
as of March 2010, and a final $5 million payment to be made when we completed
certain aggregate shipments to Solargiga.
In April
2009, we entered into an Amended and Restated Supply Agreement, or the Amended
Solargiga Supply Agreement, pursuant to which the volume of polysilicon that we
have agreed to sell to Solargiga, and that Solargiga has agreed to purchase from
us has been reduced such that up to approximately $136 million would be payable
to us during the ten-year period, subject to product deliveries and other
conditions. The Amended Solargiga Supply Agreement also extends the
date by which we are obligated to commence shipments of polysilicon from March
2010 to June 2010, and extends the dates for price adjustments and termination
rights in the event of a delay in commencing shipment. All pricing terms from
the Original Solargiga Supply Agreement remain the same. Solargiga has the right
to terminate the Amended Solargiga Supply Agreement, and recover any prepayments
made if we have not commenced polysilicon shipments by October 2010, and we have
the right to terminate the Amended Solargiga Supply Agreement, and retain all
prepayments received, if Solargiga fails to pay any of its future prepayments
when due. Pursuant to the Amended Solargiga Supply Agreement, in
addition to the initial deposit of $7 million which we received in April 2009,
Solargiga is obligated to pay us $13.4 million in four installments of $3.3
million in each of June, August, October and December 2009, with a final payment
of $200,000 upon Solargiga’s receipt of certain aggregate volumes of polysilicon
product from us.
The term
of the Amended Solargiga Supply Agreement is ten years from the date of the
first shipment. Each party, however, may terminate the Amended Solargiga Supply
Agreement at an earlier date under certain circumstances, including, but not
limited to, the bankruptcy, assignment for the benefit of creditors, liquidation
or a material breach of the Amended Solargiga Supply Agreement by the other
party. Our failure to commence shipments of polysilicon by October 2010
constitutes a material breach by us under the terms of the Amended Solargiga
Supply Agreement, among other circumstances. We have the right to terminate the
Amended Solargiga Supply Agreement upon Solargiga’s failure to pay any part of
the $13.4 million cash deposit when due. Upon Solargiga’s termination of the
Amended Solargiga Supply Agreement under certain circumstances, we are required
to refund to Solargiga all of the prepayments made as of such termination, which
was $7 million as of May 15, 2009, less any part thereof that has been applied
to the purchase price of polysilicon delivered under the Amended Solargiga
Supply Agreement. Upon a termination of the Amended Solargiga Supply Agreement
by us, we generally may retain the entire amount of prepayments made as of such
date as liquidated damages, less any part thereof that has been applied to the
purchase price of polysilicon delivered under the Amended Solargiga Supply
Agreement.
Under the
Amended Solargiga Supply Agreement, we have granted to Solargiga a security
interest in all of our tangible and intangible assets related to our polysilicon
business to serve as collateral for our obligation to repay all of Solargiga’s
prepayments made as of the date of termination, which was $7 million as of May
15, 2009, if Solargiga terminates the Amended Solargiga Supply Agreement under
certain circumstances. The security interest is subordinated to any third-party
debt we may secure to finance construction of our polysilicon production
facility and pari passu with security interests granted to each of our other
long-term polysilicon supply customers. The security interest will continue
until all of Solargiga’s prepayments have been credited against the shipment of
product, and only with respect to the amount of prepayment that has not been so
credited.
If the
contract with Solargiga is terminated for any reason, our business will be
materially harmed and we will need to secure new funds in order to finance the
construction of our polysilicon production plant. Securing new funds may delay
the anticipated timing of completion of the production plant, which delay may
result in us failing to meet our delivery requirements under our other supply
agreements. We may not be able to secure new funds on terms as favorable to us
as those under the agreement with Solargiga, or at all. If we are unable to
secure new funds, we will not be able to complete construction of the production
plant, our business will be materially harmed and we may be forced to delay,
alter or abandon our planned business operations.
Shanghai Alex New Energy Co., Ltd.
In February 2009, we entered into a fixed price, fixed volume supply
agreement with Shanghai Alex New Energy Co., Ltd., or Alex, for the sale and
delivery of polysilicon to Alex over a ten-year period, or the Alex Supply
Agreement. Under the Alex Supply Agreement, the total amount that may
be payable to us is approximately $119 million during the ten-year period,
subject to product deliveries and other conditions. Alex has paid us
cash deposits of $15 million as prepayments for future product deliveries, which
includes $5 million that was previously paid to us by Jinko, and which we and
Jinko acknowledged and agreed would be credited to the prepayment account of
Alex. See “Jiangxi Jinko Solar Co., Ltd.”, above. Alex is obligated
to pay an additional cash deposit of $5 million as a prepayment for future
product deliveries, $2 million of which is due in June 2009, and $3 million of
which is due in July 2009. The Alex Supply Agreement provides that if Alex does
not provide the $5 million cash deposit when due, then we may immediately
terminate the Alex Supply Agreement and retain all previously paid cash deposits
as liquidated damages, which was $15 million as of March 31, 2009.
The term
of the Alex Supply Agreement is ten years from the date of the first shipment.
Each party, however, may terminate the Alex Supply Agreement at an earlier date
under certain circumstances, including, but not limited to, the bankruptcy,
assignment for the benefit of creditors, liquidation or a material breach of the
Alex Supply Agreement by the other party. Our failure to commence shipments of
polysilicon by March 2010 constitutes a material breach by us under the terms of
the Alex Supply Agreement, among other circumstances. Alex’s failure
to pay any part of the $5 million cash deposit when due constitutes a material
breach of the Alex Supply Agreement by Alex, among other circumstances. In most
cases, if Alex terminates the Alex Supply Agreement, then we are required to
refund to Alex all of their prepayments as of the date of such termination,
which was $15 million as of March 31, 2009, less any part thereof that has been
applied to the purchase price of polysilicon delivered under the Alex Supply
Agreement.
Pursuant
to the Alex Supply Agreement, we have granted to Alex a security interest in all
of our tangible and intangible assets related to our polysilicon business to
serve as collateral for our obligation to repay Alex’s deposit if the Alex
Supply Agreement is terminated by Alex. Such security interest is pari passu
with security interests granted to each of our other long-term polysilicon
supply customers. The security interest will continue until all prepayments have
been credited against the shipment of product, and only with respect to the
amount of prepayment that has not been so credited.
If the
contract with Alex is terminated for any reason, our business will be materially
harmed and we will need to secure new funds in order to finance the construction
of our polysilicon production plant. Securing new funds may delay the
anticipated timing of completion of the production plant, which delay may result
in us failing to meet our delivery requirements under our other supply
agreements. We may not be able to secure new funds on terms as favorable to us
as those under the agreement with Alex, or at all. If we are unable to secure
new funds, we will not be able to complete construction of the production plant,
our business will be materially harmed and we may be forced to delay, alter or
abandon our planned business operations.
Terminated
Customer Agreements
During
fiscal 2009, we terminated one polysilicon supply contract with SANYO Electric
Co., Ltd., and reached a mutual agreement to terminate a second polysilicon
supply contract with Global Expertise Wafer Division Ltd., pursuant to
provisions in each of the respective agreements providing for a right of
termination in the event we were unable to achieve certain financing milestones
within a prescribed timeframe. As a result of these terminations, we returned a
total of $4 million in prepayments received under these contracts.
Hoku
Solar
Business
Strategy and PV Products
Our goal
is to be a leading provider in PV system installations. We plan to focus on
designing, engineering and installing turnkey PV systems and related services in
Hawaii using solar modules purchased from third-party suppliers.
Customers
Hawaii Department of
Transportation
. In October 2008, we were selected by the Hawaii State
Department of Transportation, or DOT, to design, engineer and install PV systems
at airports across the state of Hawaii and entered into a series of power
purchase agreements, or PPAs, with the DOT. Under the PPAs, the DOT will
purchase up to an aggregate of 779 kilowatts of solar electricity to be
generated by PV systems installed, owned and operated by us at a predetermined
rate over a contract period of 20 years. During the first and second quarters of
calendar year 2009, we installed PV systems at multiple DOT properties including
Lihue Airport on the island of Kauai, Kahului Airport on the island of Maui, and
Kona International Airport at Keahole and Hilo International Airport, each on
the island of Hawaii. All installations were completed in the second quarter of
calendar year 2009. As of May 2009 all of these PV systems are
operational.
In fiscal
2009, we also completed PV system installations for
Paradise Beverages, Inc.,
and Resco, Inc., and other commercial and residential customers. We also
recognized revenue from the resale of solar inventory.
Hawaiian Electric Company.
In
May 2008, the Hawaii Public Utilities Commission approved the contract for
Hawaiian Electric Company to purchase electricity generated by a PV system that
we would install. We plan to install a 218-kilowatt PV system, and sell the
power generated by that system over a 20-year period to Hawaiian Electric
Company once financing is secured. We continue to explore financing alternatives
for this project.
The James Campbell Company.
In January 2008, we began discussions with The James Campbell Company to
plan and install the PV system for the Kapolei Sustainable Energy Park, which
would be capable of generating approximately 1.5 megawatts of PV power and would
be the largest PV facility on Oahu. The discussions to date have been
non-binding to both parties, and contingent upon, among other things, receiving
certain government approvals related to the capped solid waste storage area on
the site. Discussions with The James Campbell Company are ongoing.
Our
Fuel Cell Business
Fuel
Cell Industry Overview
Based on
discussions with potential customers for our Hoku MEAs and Hoku Membranes during
fiscal 2007, we determined that the potential for future revenue opportunities
from our Hoku Fuel Cells division was uncertain. As a result, we do not plan on
actively pursuing any new contracts or committing material resources to further
develop our fuel cell products. We will, however, assess the financial viability
of any new opportunities that may arise on a case-by-case basis.
Customers
We do not
presently have any material customer contracts for our Hoku MEA or Hoku
Membranes.
Backlog
As of
March 31, 2009, we have entered into PV system installation and other related
service contracts that we have not completed; however, we do not have a
backlog.
Sales
and Marketing
We have
one employee that is dedicated to sales for our PV system installation business
in Hawaii. We are offering the sale and installation of our turnkey PV systems
or the option of a power purchase arrangement where we would install and own the
solar system and the end user would pay us for the electricity produced under a
long-term contract.
Research
and Development
Hoku
Materials and Hoku Solar
We are
still at an early stage in our expansion into the polysilicon and PV module
market and have not, to date, conducted any research and development in this
area.
Our
research and development expenses were $0, $86,000 and $1.8 million in fiscal
2009, 2008 and 2007, respectively, and all such expenses were related to our
fuel cell business. As of March 31, 2009, we had no individuals on our research
and development team for our solar or fuel cell businesses.
Intellectual
Property
Hoku
Materials and Hoku Solar
We are
still at an early stage in our expansion into the polysilicon and PV systems
installation market and have not developed or licensed any proprietary
intellectual property addressed to this market. We may need to obtain licenses
to manufacture and/or sell polysilicon and PV modules using the technology that
we are planning to implement. However, based on our discussions with engineering
firms and equipment suppliers, we believe that we have obtained all necessary
licenses from these engineering firms and turnkey equipment suppliers that are
required to manufacture, market and/or sell the products made with their
equipment.
Manufacturing
Hoku Materials
In
September 2008, we announced that we would be increasing our planned polysilicon
facility capacity from 3,500 metric tons per year to 4,000 metric tons per year.
Our original estimated construction cost for a facility capable of producing
3,500 metric tons of polysilicon per year was $390 million. We do not believe we
will require significant additional capital to increase our facility capacity to
4,000 metric tons per year; however, we are continuing to review the $390
million estimated cost to complete the plant. This estimate is based on our
discussion with vendors, declining costs of materials and labor and ongoing
adjustments of certain design elements; however, changes in costs, modifications
in construction timelines and other factors could cause the actual cost to
significantly exceed our $390 million estimate. Alex, Suntech, Solarfun, Jinko,
Tianwei and Solargiga have collectively committed to contribute, in the form of
polysilicon supply prepayments, $243.4 million towards these costs, subject to
certain conditions and the achievement of various milestones and repayment
obligations under certain circumstances. As of May 31, 2009, we had collected
$155.5 million of combined prepayments that were committed to us from Alex,
Suntech, Solarfun, Jinko, Tianwei and Solargiga. Additionally, as of March 31,
2009, we had contributed approximately $41 million to the construction cost
of our polysilicon plant. Assuming the total cost to complete the construction
of our 4,000 metric ton plant is $390 million, that our existing polysilicon
customers make their prepayments in full when due and that we are able to secure
additional prepayments from one or more new polysilicon customers, we believe we
will need to raise through one or more debt or equity offerings for the
procurement and construction of our planned polysilicon manufacturing facility
an amount ranging between $35 million and $55 million. If we are unable to
secure one or more additional long-term polysilicon supply contracts and
additional customer prepayments, assuming the cost to complete construction of
the plant is $390 million and that our existing polysilicon customers make
timely prepayments in full, the amount we may need to raise could be as much as
$106 million. If we are unable to secure one or more additional long-term
polysilicon supply contracts and additional customer prepayments, if one or more
of our polysilicon supply customers fail to meet their obligations to make
timely prepayments and/or the actual cost to complete the plant is more than
$390 million, the amount we may need to raise could exceed $106
million.
In fiscal
2009, reductions and delays in customer prepayments caused a shift of our
planned production demonstration for our polysilicon plant from the first
quarter of calendar year 2009, to the third quarter of calendar year 2009,
and a shift of our planned first commercial polysilicon shipment from the
first half of calendar year 2009 to the second half of calendar year 2009. These
reductions and delays in customer prepayments also have caused a delay in the
construction of our on-site TCS production facility. We plan to ramp-up
production throughout the second half of calendar year 2009 and into calendar
year 2010, when we expect to reach full production capability in the first
quarter of calendar year 2010. There are no assurances, however, that we will
not need to further revise our planned schedule.
City of Pocatello.
In March
2007, we entered into a 99-year ground lease with the City of Pocatello, Idaho,
for approximately 67 acres of land and, in May 2007, the City of Pocatello
approved an ordinance that authorizes the Pocatello Development Authority to
provide us certain tax incentives related to certain necessary infrastructure
costs we incur in the construction and operation of our polysilicon plant. In
May 2009, we entered into an Economic Development Agreement, or the PDA
Agreement, with the Pocatello Development Authority, or PDA, pursuant to which
PDA agreed to reimburse to us amounts we actually incur in making certain
infrastructure improvements consistent with the North Portneuf Urban Renewal
Area and Revenue Allocation District Improvement Plan and the Idaho Urban
Renewal Law, or the Infrastructure Reimbursement, and an additional amount as
reimbursement for and based on the number of full time employee equivalents
we create and maintain, or the Employment Reimbursement, at the
production facility under construction in Pocatello, Idaho, or the
Plant. The parties agreed that (a) the Infrastructure Reimbursement
will be an amount that is equal to 95% of the tax increment payments PDA
actually collects on the North Portneuf Tax Increment Financing District with
respect to our real property and improvements located in such district, or the
TIF Revenue, up to approximately $26 million, less the actual Road Costs
(defined below), and (b) the Employment Reimbursement will be an amount that is
equal to 50% of the TIF Revenue, up to approximately $17
million. Each of the Infrastructure Reimbursement and the Employment
Reimbursement will be made to us over time as TIF Revenue is received, and only
after the costs of completing a public access road to the Plant, in an amount
not to exceed $11 million, or the Road Costs, has been paid to PDA out of TIF
Revenue, and up to $2 million in capital costs has been paid to the City of
Pocatello out of TIF Revenue.
Stone & Webster, Inc.
In
August 2007, we entered into an Engineering, Procurement and Construction
Management Contract with Stone & Webster, Inc., or S&W, a subsidiary of
The Shaw Group Inc., for engineering, procurement, and construction management
services for the construction of our polysilicon production plant, which was
amended in October 2007 by Change Order No. 1, and again in April 2008 by Change
Order No. 2, which are collectively the S&W Engineering Agreement. Under the
S&W Engineering Agreement, S&W was to provide all engineering,
procurement and construction management services necessary to complete the
design and planning for construction of our polysilicon plant, which had a
production capacity at that time of 3,500 metric tons per year. S&W was to
be paid on a time and materials basis plus a fee for its services and incentives
if certain schedule and cost targets were met. The target cost for the services
to be provided under the S&W Engineering Agreement was $50 million, plus up
to $5.0 million of incentives that would be payable if certain cost and schedule
milestones were achieved.
In
February 2009, we and S&W agreed to Change Order Number 3 under the S&W
Engineering Agreement, or S&W Change Order 3, to, among other things: (i)
increase the rated polysilicon production capacity of our planned facility to up
to 4,000 metric tons per year; (ii) eliminate construction management services
from S&W’s scope of work; (iii) confirm the suspension of detailed
engineering services for our planned TCS production plant; (iv) remove $5
million of incentives that may have been payable if certain cost and schedule
milestones were achieved; and (v) allocate, based on specific dates, up to an
aggregate of $1 million of liquidated damages that S&W would pay to us if
engineering deliverables are not provided to us on or before such dates. S&W
may not be required to pay liquidated damages if S&W fails to meet a
deliverable date because we or our other contractors cause a delay, or request
changes to the work that increase the time for completion, or if force majeure
causes a delay.
The
target cost for the services to be provided under the S&W Engineering
Agreement, as modified by S&W Change Order 3, is unchanged at $50 million,
and the $5.0 million of incentives that may have been payable was eliminated.
Pursuant to the S&W Engineering Agreement, as modified by S&W Change
Order 3, S&W does not guarantee that the target cost will be met, and we are
obligated to pay for S&W's services regardless of whether this cost target
is ultimately achieved. During fiscal 2009, we made payments to
S&W of $28 million, and as of March 31, 2009, we had paid S&W an
aggregate amount of $32 million.
JH Kelly LLC
. In August 2007,
we entered into a Cost Plus Incentive Contract with JH Kelly LLC, or JH Kelly,
for construction services for the construction of our planned polysilicon
production plant, which was amended in October 2007, by Change Order No. 1, and
again in April 2008 by Change Order No. 2, which are collectively the JH Kelly
Construction Agreement. Under the JH Kelly Construction Agreement, JH Kelly
agreed to provide construction services as our general contractor for the
construction of our polysilicon plant with production capacity of, at that time,
3,500 metric tons per year. The target cost for the services to be provided
under the JH Kelly Construction Agreement was $145 million, including up to $5.0
million of incentives that may have been payable under certain
circumstances.
In March
2009, we and JH Kelly agreed to Change Order No. 3 under the JH Kelly
Construction Agreement, or JH Kelly Change Order 3, to, among other things: (i)
increase the rated polysilicon production capacity of our planned facility to up
to 4,000 metric tons per year; (ii) confirm our planned schedule to include a
reactor test demonstration in June 2009, the partial commercial operation of our
plant in September 2009, and full commercial operation of our plant in March
2010; (iii) reallocate the $5 million of incentives that may be payable such
that $3.5 million of the incentives may be payable if JH Kelly achieves the
foregoing schedule milestones, $1 million of the incentives may be payable if JH
Kelly’s actual costs are less than $145 million, and $500,000 may be payable if
JH Kelly achieves certain safety goals during the construction of the plant. Any
incentives that are earned would be paid after final completion of the
plant.
Pursuant
to the JH Kelly Construction Agreement, as modified by JH Kelly Change Order 3,
JH Kelly does not guarantee that the cost or schedule targets will be met, and
there can be no assurances that either such target will be met. Moreover, we are
obligated to pay for JH Kelly's services regardless of whether these targets are
ultimately achieved; however, JH Kelly is required to pay liquidated damages of
up to $1 million for construction schedule delays that are directly caused by
the fault of JH Kelly. During fiscal 2009, we made payments to JH
Kelly of $41.2 million, and as of March 31, 2009, we had paid JH Kelly an
aggregate amount of $45.5 million.
Dynamic Engineering Inc.
In
October 2007, we entered into an agreement with Dynamic Engineering Inc., or
Dynamic, for design and engineering services, and a related technology license
for the process to produce and purify trichlorosilane, or TCS. Under the
agreement with Dynamic, or the Dynamic Agreement, Dynamic is obligated to design
and engineer a TCS production facility that is capable of producing 20,000
metric tons of TCS for our planned 4,000 metric tons per year polysilicon
production plant. The Dynamic process is to be integrated by S&W into the
overall polysilicon production facility, and will be constructed by JH Kelly.
Under the Dynamic Agreement, Dynamic's engineering services are provided and
invoiced on a time and materials basis, and the license fee will be calculated
upon the successful completion of the TCS production facility, and demonstration
of certain TCS purity and production efficiency capabilities. The maximum
aggregate amount that we may pay Dynamic for the engineering services and the
technology license is $12.5 million, which includes an incentive for Dynamic to
complete the engineering services under budget. Dynamic is guaranteeing the
quantity and purity of the TCS to be produced at the completed facility, and has
agreed to indemnify us for any third-party claims of intellectual property
infringement. During fiscal 2009, we made payments to Dynamic of $3.6 million,
and as of March 31, 2009, we had paid Dynamic an aggregate amount of $4.8
million.
GEC Graeber Engineering Consultants
GmbH and MSA Apparatus Construction for Chemical Equipment Ltd.
We
entered into a contract with GEC Graeber Engineering Consultants GmbH, or GEC,
and MSA Apparatus Construction for Chemical Equipment Ltd., or MSA, for the
purchase and sale of 16 hydrogen reduction reactors and hydrogenation reactors
for the production of polysilicon, and related engineering and installation
services. Under the contract, we will pay up to a total of 20.9 million Euros
for the reactors. The 16 reactors are designed and engineered to produce
approximately 2,000 metric tons of polysilicon per year. The term of the
contract extends until the end of the first month after the expiration date of
the warranty period, but may be terminated earlier under certain circumstances.
During fiscal 2009, we made payments to GEC and MSA of 8.9 Euros or $13.5
million and, as of March 31, 2009, we had paid GEC and MSA an aggregate amount
of 15.2 Euros or $22.3 million.
In
January 2009, we received the first shipment of six Siemens-process reactors at
our facility in Pocatello, Idaho, and all of these polysilicon reactors have
been assembled and put into place on our production floor. The reactors are the
first units to arrive in Pocatello out of a planned total order of 28. The next
shipment of 10 polysilicon reactors and related equipment is scheduled to arrive
at our facility no later than the third quarter of calendar year
2009.
We are in
discussions with GEC to purchase additional 12 reactors necessary for our
planned annual capacity of 4,000 metric tons of polysilicon. The cost
of these additional reactors is not expected to be greater than 20.9 million
Euros.
Idaho Power Company
. In
December 2007, we entered into an agreement with Idaho Power Company, or Idaho
Power, to complete the construction of the electric substation to provide power
for our planned polysilicon production plant, or the Idaho Power Agreement. We
are obligated to pay Idaho Power an aggregate of $14.8 million for the
completion of the substation and associated facilities. Under the terms of the
Idaho Power Agreement, the substation and associated facilities were scheduled
to be completed in February 2009. The Idaho Power Agreement provided that Idaho
Power could invoice us additional amounts for temporary power to enable the
start-up and operation of the planned polysilicon production plant prior to
February 2009.
In
September 2008, we amended and restated the Idaho Power Agreement by entering
into an Amended and Restated Agreement for Construction of the Hoku Electric
Substation and Associated Facilities, or the Amended Idaho Power Agreement.
Under the Amended Idaho Power Agreement, Idaho Power agreed to construct an
electric substation and associated transmission facilities with an increased
capacity beyond what was provided for in the original Idaho Power Agreement.
Idaho Power estimated that the costs of construction under the Amended Idaho
Power Agreement would increase to approximately $16.5 million. The Amended Idaho
Power Agreement also provides that upon completion of construction, there would
be a true-up of actual construction costs, so that either we would be refunded
any monies we had paid to Idaho Power over and above the actual costs of
construction, or we would pay Idaho Power any additional construction costs
beyond the original amount. Idaho Power agreed to use commercially reasonable
efforts to provide us with transmission services for specified wattages by May
2009, and July 2009, and to complete construction of the expanded electric
substation and associated transmission facilities by August
2009. Pursuant to the Amended Idaho Power Agreement, during fiscal
2009, we made payments to Idaho Power of $12.9 million, and as of March 31,
2009, we had paid Idaho Power Company an aggregate amount of $17.5 million,
which is $1 million more than Idaho Power’s estimate under the Amended Idaho
Power Agreement.
In
September 2008, we also entered into an Electric Service Agreement with Idaho
Power for the supply of electric power and energy to us for use in our
polysilicon facility, subject to the approval of Idaho’s Public Utilities
Commission, or the ESA. The term of the ESA is four years, beginning in June
2009. During the term of the ESA, Idaho Power agrees to make up to 82,000
kilowatts of power available to us at certain fixed rates, which are subject to
change only by action of the Idaho Public Utilities Commission. After the
initial term of the ESA expires, either we or Idaho Power may terminate the ESA
without prejudice. If neither party chooses to terminate the ESA, then Idaho
Power will continue to provide electric service to us at the same fixed
rates.
In May
2009, we reached an agreement, or the Letter Agreement, with Idaho Power to
amend certain provisions of the ESA, which amendment, or the ESA Amendment,
would be filed with, and is conditioned and effective only upon approval by, the
Idaho Public Utilities Commission, or PUC. The ESA Amendment, if
approved by the PUC, would extend by six months the date when we are obligated
to begin purchasing prescribed amounts of electricity from Idaho Power, from
June 1, 2009 to December 1, 2009. The ESA Amendment also would
provide for (a) electricity to be provided to us by Idaho Power at the current
tariff rate through November 30, 2009, (b) a commitment by us to take no more
than 5 megawatts, or MW, of electric power through July 2009, 10 MW during
August 2009 and 25 MW from September through November 2009, (c) a reduction in
the levels of electric power to be provided under the ESA to 43 MW during the
period of June 16, 2012 through August 15, 2012, and to 67 MW during the period
of August 16, 2009 to September 15, 2009, and (d) certain charges, referred to
as the Schedule 91 Energy Efficiency Rider, that would be added to a portion of
the electricity demand charges set forth in the ESA, beginning on December 1,
2011. The Schedule 91 Energy Efficiency Rider is to recover costs
incurred by Idaho Power associated with providing energy efficiency services and
programs to its customers.
AEG Power Solutions USA Inc.
(formerly known as Saft Power Systems USA, Inc.).
In March 2008, we
entered into an agreement with AEG Power Solutions USA Inc., or AEG, formerly
known as Saft Power Systems USA, Inc., or the AEG Agreement, for the purchase
and sale of thyroboxes, earth fault detection systems, and related technical
documentation and services, or the Deliverables. Under the AEG Agreement, AEG
was obligated to manufacture and deliver the Deliverables, which are used as the
power supplies for the polysilicon deposition reactors to be used in our planned
polysilicon production plant. The total fees payable to AEG for all
Deliverables under the AEG Agreement was approximately $13 million, which was
payable in installments, the first of which was made in April 2008.
In May
2009, we entered into an Amendment to the AEG Agreement, or the AEG
Amendment. Under the AEG Amendment, the total fees to be paid to AEG
remain approximately $13 million, including approximately $1.2 million that was
previously paid, and the payment and delivery schedule was restructured such
that we are obligated to make payments of $500,000 on or before June 3, 2009,
$500,000 on or before June 29, 2009, $615,000 on or before July 31, 2009 and
$2,100,000 on or before August 31, 2009, related to certain Deliverables that
AEG is obligated to ship in August 2009. After such shipment has
occurred, we are obligated to make payments of $800,000 on or before September
30, 2009, $813,995 on or before October 30, 2009, $906,795 on or before November
30, 2009 and $1,686,682 on or before December 21, 2009, related to the remaining
Deliverables which AEG is obligated to ship in October and December
2009. During fiscal 2009, we made payments to AEG of $5.2 million,
and as of March 31, 2009, we had paid AEG an aggregate amount of $5.2
million.
Polymet Alloys, Inc.
In
November 2008, we entered into an agreement with Polymet Alloys, Inc., or
Polymet, for the supply of silicon metal to us for use in our planned
polysilicon production facility in Pocatello, Idaho. The term of the agreement
was three years, commencing in January 2009. Each year during the term of the
agreement, Polymet agreed to sell to us, and we agreed to purchase from Polymet,
specified volumes of silicon metal that meet certain purity and size
specifications. The volume was fixed during each of the three years; provided
that the parties could agree to increase the volume. Pricing was fixed during
calendar year 2009, and the aggregate net value of the silicon metal products to
be purchased by us under the agreement in calendar year 2009 was approximately
$6.5 million. In May 2009, we entered into an amended and restated supply
agreement with Polymet, or the Amended Polymet Agreement. Under the
Amended Polymet Agreement, we revised the date of our first shipment from
calendar year 2009 to calendar year 2010, and increased our purchase commitment
to no less than 65% of our annual silicon metal requirement. Pricing
is to be negotiated for each year of the agreement; however, if the parties are
unable to agree on pricing for any year, or we have agreed to purchase less than
the amount specified in the Amended Polymet Agreement, Polymet has a right of
first refusal to match the terms offered by any third-party supplier from whom
we may seek to purchase silicon metal. Either party may also
terminate the agreement under certain circumstances, including a material breach
by the other party that has not been cured within a specified cure period, or
the other party’s voluntary or involuntary liquidation. As of March 31, 2009, we
have not made any payments to Polymet.
PVA Tepla Danmark.
In April
2008, we entered into an agreement with PVA Tepla Danmark, or PVA, for the
purchase and sale of slim rod pullers and float zone crystal pullers. Under the
agreement, PVA is obligated to manufacture and deliver the slim rod pullers and
float zone crystal pullers for our planned 4,000 metric tons per year
polysilicon production plant. Slim rod pullers are used to make thin rods of
polysilicon that are then transferred into polysilicon deposition reactors to be
grown through a chemical vapor deposition process into polysilicon rods for
commercial sale to our end customers. The float zone crystal pullers convert the
slim rods into single crystal silicon for use in testing the quality and purity
of the polysilicon. The total fees payable to PVA is approximately $6 million,
which is payable in four installments, the first of which was made in August
2008. We expect to receive the deliverables under our contract with PVA in the
third quarter of calendar year 2009. Either party may terminate the agreement if
the other party is in material breach of the agreement and has not cured such
breach within 180 days after receipt of written notice of the breach, or if the
other party is bankrupt, insolvent, or unable to pay its
debts. During fiscal 2009, we made payments to PVA of $1.9 million
and, as of March 31, 2009, we had paid PVA an aggregate amount of $1.9
million.
BHS Acquisitions, LLC.
In
November 2008, we entered into an agreement with BHS Acquisitions, LLC, or BHS,
for the supply of hydrochloric acid, or HCl, to us for use in our planned
polysilicon production facility in Pocatello, Idaho. The term of the agreement
is eight years beginning on the date on which the first shipment of product is
delivered. Each year during the term of the agreement, BHS has agreed to sell to
us, and we have agreed to purchase from BHS, specified volumes of HCl that meet
certain purity specifications. The volume is fixed during each of the eight
years. Pricing is fixed for the first twelve months of shipments, which are
scheduled to begin no later than January 2010, and the aggregate net value of
the HCl to be purchased by us under the agreement in the first twelve months is
approximately $2.4 million. Pricing is to be renegotiated for each of the
remaining years of the agreement; however, if the parties are unable to agree on
pricing for any future year, then either party may terminate the agreement
without liability to the other party. Either party may also terminate the
agreement under certain circumstances, including a material breach by the other
party that has not been cured within a specified cure period, or the other
party’s voluntary or involuntary liquidation. As of March 31, 2009, we have not
made any payments to BHS.
Hoku
Solar
In June
2007, we announced our strategy to focus on the sale of turnkey PV system
installations, and related services, and our plan not to enter the solar module
manufacturing business.
Due to
our decision not to enter the solar-module manufacturing business along with
reduced activity in our fuel cell business, in December 2008, we sold our real
property and improvements, including our corporate headquarters, in Kapolei,
Hawaii, or the Property. The Property was sold for an aggregate purchase price
of $5.8 million.
In
December 2008, we and UFA Renewable Energy Fund I, LLC, a Delaware limited
liability company, or UFA, established and capitalized Hoku Solar Power I, LLC,
a California limited liability company, or Power I. Under the terms of the Power
I Operating Agreement by and between us and UFA, or the Operating Agreement, we
assigned our power purchase agreements, or PPAs, to Power I, which was created
to own and operate each system and which will sell the electricity generated by
the PV systems to the Hawaii State Department of Transportation, or DOT, at
predetermined contract rates. Under the terms of the PPAs, Power I is
permitted to install, maintain and operate each of the seven planned energy
systems on DOT facilities over a term of 20 years, commencing on the date that a
system becomes operational and energy is delivered to DOT.
In
December 2008, we entered into a Development Services Agreement with Power I, or
the Development Agreement, pursuant to which we agreed to construct, install,
develop and commission the PV systems on behalf of Power I. We also
agreed to operate and maintain the systems pursuant to the terms and conditions
of the Purchase and Sale and Operation and Maintenance Agreement entered into
between us and Power I in December 2008. Each system will be transferred to
Power I prior to the commencement of commercial operation. In December 2008, we
completed the engineering, design and procurement phases for the projects and
commenced system installation at two DOT project sites on the island of
Kauai. In March 2009, the two PV systems in Kauai have been completed
and transferred to Power I. As of April 30, 2009, installation of the
remaining five PV systems was completed and the DOT has provided letters of
system acceptances on each of the seven PV systems, acknowledging that various
system requirements, including, but not limited to, system completion, permit
certification, and energy capacity, have been satisfied in accordance with the
provisions of the PPA. As of May 2009, all of these PV systems are
operational.
Hoku
Fuel Cells
We are
not currently manufacturing any Hoku Membranes or Hoku MEA products due to
reduced activity in our fuel cell business.
Supplier
Relationships
We
utilize solar modules purchased through our supply relationship with Suntech and
Sanyo, among others, for our PV system installations. We have structured our
agreements as firm purchase orders at a predetermined price or non-binding
forecasts of our annual or quarterly product needs to our suppliers, and then
periodically issue purchase orders for specific projects. These suppliers are
generally under no legal obligation to supply solar modules until they have
accepted our purchase orders. Additionally, as part of the Alex Supply
Agreement, through its PV module manufacturing subsidiary, Alex has agreed to
provide us with discounted original equipment manufacturing (OEM) services for
up to a certain amount of PV modules per year for each year of their polysilicon
supply contract. The OEM manufacturing service would be at our sole option and
would be priced at Alex's most preferred rate. Additionally, as part of the
Jinko Supply Agreement, Jinko has agreed to provide discounted wafer
manufacturing (tolling) services to us for up to a certain amount of polysilicon
per year for each year of their polysilicon supply contract. This tolling
service would be at our sole option and will be priced at Jinko's most preferred
rate.
Competition
Hoku
Materials
In the
polysilicon market, we will compete with companies such as Hemlock Semiconductor
Corporation, Renewable Energy Corporation ASA, Mitsubishi Polycrystalline
Silicon America Corporation, Mitsubishi Materials Corporation, Tokuyama
Corporation, MEMC Electronic Materials, Inc., and Wacker Chemie AG. In addition,
new companies are emerging in China, Korea, India, Europe, Brazil, Australia,
North America, and the Middle East, and new technologies, such as fluidized bed
reactors, are emerging which may have significant cost and other advantages over
the Siemens process we are planning to use to manufacture polysilicon. These
competitors may have longer operating histories, greater name recognition and
greater financial, sales and marketing, technical and other resources than us.
If we fail to compete successfully, we may be unable to successfully enter the
market for polysilicon.
After a
period of polysilicon supply shortages, an essential raw material in the
production of PV modules, overall polysilicon supply increased in fiscal 2009.
We believe that supply increases will continue through at least fiscal 2010, and
potentially for a longer period, with the possibility of an oversupply of
polysilicon in fiscal 2011. In the near term, however, we believe that the
demand for polysilicon will support further competition in the polysilicon
market. Increasing polysilicon supply, however, has and will continue to
suppress spot market prices, which could adversely affect our ability to secure
additional long-term supply contracts, or to secure such contracts on favorable
terms.
Hoku
Solar
The
market for PV installations is competitive and continually evolving. As a new
entrant to this market, we expect to face substantial competition from companies
such as SunPower Corporation, SunEdison, REC Solar and other new and emerging
companies in Hawaii, Asia, North America and Europe. Some of our known
competitors are established players in the solar industry, and have a stronger
market position than ours and have larger resources and recognition than we
have. In addition, the PV market in general competes with other sources of
renewable energy and conventional power generation. In the near term, we believe
that the demand for PV installations will support further competition in the
market, enabling us to sell our services, specifically in Hawaii where we are
headquartered.
Hoku
Fuel Cells
We are
not actively seeking new contracts; however, we will assess the financial
viability of any new opportunities that may arise on a case-by-case
basis.
Government
Regulation
Hoku
Materials and Hoku Solar
The
market for electricity generation products is heavily influenced by foreign,
federal, state and local government regulations and policies concerning the
electric utility industry, as well as policies promulgated by electric
utilities. These regulations and policies often relate to electricity pricing
and technical interconnection of customer-owned electricity generation. In the
United States and in a number of other countries, these regulations and policies
are being modified and may continue to be modified. Customer purchases of, or
further investment in the research and development of, alternative energy
sources, including solar power technology, could be deterred by these
regulations and policies, which could result in a significant reduction in the
potential demand for our solar products. For example, without a regulatory
mandated exception for solar power systems, utility customers are often charged
interconnection or standby fees for putting distributed power generation on the
electric utility grid. These fees could increase the cost to consumers of solar
power systems, which could decrease the market for PV installations, thereby
harming our business, prospects, results of operations and financial
condition.
The
installation of PV systems is subject to oversight and regulation in accordance
with national and local ordinances relating to building codes, safety,
environmental protection, utility interconnection and metering and related
matters. It is difficult to track the requirements of individual states and
design equipment to comply with the varying standards. Any new government
regulations or utility policies pertaining to PV systems may result in
significant additional expenses to us and, as a result, could cause a
significant reduction in demand for PV installations. In addition, the
manufacture of polysilicon will involve the use of materials that are hazardous
to human health and the environment, the storage, handling and disposal of which
will be subject to government regulation. Under various Federal, state and local
laws, ordinances and regulations, an owner or operator of real estate is liable
for costs of removal or remediation of certain hazardous or toxic substances on
or in such property. These laws often impose such liability without regard to
whether the owner or operator knew of, or was responsible for, the presence of
such substances.
Federal
and Hawaii state tax credits are available for residential and commercial PV
systems placed in service. In October 2008, Congress extended the availability
of the federal tax credit for both residential and commercial solar
installations to 2016. Additionally, in February 2009, the American Recovery and
Reinvestment Act, or ARRA, was signed into law, which contains various programs
and taxpayer incentives with respect to renewable energy that could benefit us.
We are examining, but have not yet determined if, or to what extent, the ARRA
renewable energy incentives might benefit us.
Financial
Information by Business Segment and Geographic Data
In fiscal
2009, 100% of our total revenue was from our PV system installations and other
related services and the resale of solar inventory primarily from our contracts
with Paradise Beverages, Inc., and Resco, Inc. All of the revenue was generated
from customers in the United States. In fiscal 2008, 59% of our total revenue
was from our PV system installations, primarily from our contracts with Paradise
Beverages and Hardware Hawaii, and the remaining 41% of revenue was from our
fuel cell contracts with the U.S Navy. All of the revenue was generated from
customers in the United States. In fiscal 2007, all of our revenue was derived
from our fuel cell business. In fiscal 2007, our revenue was from the U.S. Navy,
Nissan and Sanyo, 40% in the aggregate of which was from Nissan and Sanyo, which
are located in Japan.
Employees
As of
March 31, 2009, we had 28 employees, consisting of 10 in Hoku Materials, 8 in
Hoku Solar and the remaining 10 employees are general administrative employees
in Hoku Scientific that provide support for all divisions, public company
requirements and other corporate initiatives.