ARTIPHYCTION
Project full title: “Fully artificial photo-electrochemical device
for low temperature hydrogen production”
Contract no.: 303435
Reference call.: FCH-JU 2011
Date of preparation of Annex I (latest version): 19/06/2015
Date of approval of Annex I by FCH JU: 26/06/2015
Start date of contract: 01/05/2012
Duration: 42 months
Deliverable Nr: D7000.7
“Report on the study on the potential future penetration of the
ArtipHyction technology in the devised or in spin-off fields”
Dissemination Level: PU
Planned Delivery: Month 42
Actual Delivery: Month 45
Leading Partner: POLITO (Project coordinator: Guido Saracco)
Revision: V1
Status: Accepted
Artiphyction – Project n. 303435
1.
Deliverable 7000.7
Introduction
The present document reports on the technical and economical evaluation of the photo-electrocatalytic (PEC)
ArtipHyction technology for the generation of green hydrogen. It is derived from studies performed on
technology implementation perspectives and related energy scenarios. The purpose of this report is the
evaluation of the potential penetration of the ArtipHyction technology as a function of the achieved
performance and durability. Hence, it could be possible to set new targets for subsequent R&D work on the
ArtipHyction concept, to achieve the penetration of this technology in the worldwide energy scenario and to
devise possible spin-off applications.
Since, the PEC technology in general does not offer any footprint specific improvements when compared to
conventional PV plus electrolysis, the motivation and vision of this kind of systems is that hydrogen
production costs using PEC technology may eventually be lower than those resulting from the combination of
PV modules and electrolysers.
The present document tries to explain the environmental and economic advantages, the safety of the system
and the easy installation. The ArtipHyction device in fact has a similar or even broader application potential of
fuel cells or photovoltaics. It holds the same modularity of these reference technologies, so that a user can
add or subtract as many as are necessary for the application, in a very flexible and non-cumbersome way.
2
This report first summarizes the main features of the design of the pilot scale 1.6 m hydrogen generation unit
and explains the methodology used for the hydrogen production cost estimatation. The cost calculations for
the current economic conditions are then presented, and the results are commented.
The unit is evaluated for two efficiency scenarios, one at 2%, which is the operating efficiency of the
Artiphiction prototype targeting 10.000 hrs of operation (see D6.3), and the other at 5%, which is a higher
efficiency that some works in the literature have achieved.
Revision: V1
Status: to be approved
2
Artiphyction – Project n. 303435
Deliverable 7000.7
2.1 Design of ArtipHyction prototype
Technology Description
In a first phase of the project, the single module test-rig developed have the following specification:
- maximized electrode active area: 80 x 80 mm;
- electrode electrical collectors finger type;
- cathode/anode gas production separation;
- water flow distribution;
- low distance between electrodes;
- activation bias via photovoltaic cell pattern;
- multiple device configuration;
- several electrical connection configurations on PV possible;
- compact design.
In the second phase, within the task 6200 the work has been dedicated to the definition of preliminary
possible versions of novel device designs (single modules) that have then evolved into assemblies of modular
units, containing different amounts of single cells (i.e. the first multiple modules unit was built with a total of
9 integrated cells, but in following it evolved to a string of 5 single cells). These designs were subsequently
optimized to achieve the executive design, manufacturing and assembly of the Artyphiction device (tasks
6300 and 6400) for its further tests within the task 6500.
The evolution of the design and size (referred to the photo-active area of the BiVO4 electrode) of the
prototype is shown in following:
2
The first single PEC cell module (of 64 cm of photo-active area) was made in Teflon in order to guarantee a
high resistance/ inertness for all the preliminary tests (see D 6.2 for more details). Nevertheless, in order to
reduce the weight, the distance between the electrodes and the cost of the housing, its material was changed
for PVC. The distribution of liquid flow on inlets and outlets was investigated via experimentation and
simulations on the single module device (see Fig.s 5 a,b) so that both the electrolyte and the produced gases
(O2 and H2) flow naturally from the bottom to the top of the device for a subsequent separation.
Revision: V1
Status: to be approved
3
Artiphyction – Project n. 303435
(a)
Deliverable 7000.7
(b)
Figure 5: Fist single module test-rig: (a) Executive designs and pictures of the manufactured device; (b) experiments with
Mo-doped BiVO4 electrodes and (c) fluidodynamic simulations
2
During the assembly of the 9 PEC cells unit (with photo-active area of 580 cm ) different problems were faced
to maintain the hydraulic sealing, which necessity to test of several different gaskets in order to guarantee a
good sealing of the system and to avoid leakage of both gases and liquids as well as the damage of the glass
supported anodic electrodes. Therefore, for the final prototype, a string of 5 single PEC cells coupled together
was selected as the optimum design, which guarantee an easier management of the internal hydraulic on the
system, a good sealing and an easiest closure of the module. This 5 PEC cells module has a dimension of: 580 x
124 mm, and a thickness of 29 mm.
Figure 1: Schematic and image of the ArtipHyction cell
The module of 5 PEC cells was designed to constitute the panel formed by several of this modules until
Revision: V1
Status: to be approved
4
Artiphyction – Project n. 303435
Deliverable 7000.7
2
reach the desired final photoactive area of the final Artiphyction device (1.6 m ).
Tilting System
Pumps Rack & System Stabilizer
Cathode Column Flow Inlet Collector
Anode Column Flow Inlet Collector
Cathode Column Flow Outlet Collector & Gas Separator
Anode Column Flow Outlet Collector & Gas Separator
2
Figure 2: Schematic and image of the ArtipHyction 1.6 m prototype
Revision: V1
Status: to be approved
5
Artiphyction – Project n. 303435
Deliverable 7000.7
2
Figure 3: Schematic and image of the ArtipHyction 1.6 m prototype
The key characteristics of the final design are summarized in following:









A baffle in front of inlet channel helps electrolyte distribution on opposite sides of electrode. Inlet of
electrolyte flows in a collector chamber to keep down flow velocity. Each single inlet spot has a
calculated thru surface helping flatten differential pressure between each flow channel.

The distance between the active surfaces of the electrodes is about 7.5 millimeters, by using a Gas
Diffusion electrode in the cathodic side. This dimension takes in account mechanical manufacturing
and strength of structure.

Flow channels are machined in the width of diffuser layer and external frame needs to be strong
enough to compress gaskets throughout the system.

Assembly is a sandwich design cell with gaskets to avoid electrolyte/gas leakage. Correct amount of
compression is assured by 10 M5 A2 bolts treaded on PV frame steel inserts to avoid stripping of
polymeric material.

Activation of chemical reactions is made by a bias via photovoltaic (PV) cell system. The unutilized
area around the electrode window will be used for the PV cells installation (6 PV cells were mounted
in each string of 5 PEC cells). Monocrystalline Si PV cells in were purchased for such purpose and have
the following specifications:


Power: 0.88 W


Working voltage: 5.5 V


Working Current: 160 mA


Dimensions: 3.54 in x 1.5 in x 0.12 in (9 cm x 3.8 cm x 0.3 cm)

Weight: 0.81 oz (23 g)

2
Each PEC cell on the final device has been assembled using a Co-Pi-catalyzed 3%Mo-BiVO4 anode (10x10 cm ),
2
a Nafion 117 membrane for O2-H2 separation and a Co-based cathode (10x10 cm ):
Revision: V1
Status: to be approved
6
Artiphyction – Project n. 303435
Deliverable 7000.7
2
Pilot unit 1.6 m Operation Description
The system made of 20 strings of 5 cells each is mounted on a dedicated hardware including a tilting system
to manually regulate the actual angle of sun exposition. The back of the panel hosts the anodic and cathodic
fluidic circuit and electrolyte reservoir. For the pilot system 2 pumps are included in the sustaining column of
the panel. For easier experimental characterization of the system the kind of pump selected is centrifugal with
a by-pass regulation of the flow added. In future evolution of this concept a consistent saving in cost and
energy consumption could be achieved by using different kind of pump derived from mass production (i.e.
membrane pumps).
The mechanically completed system is exposed to the sun irradiation (or artificial lamps for testing purposes)
and the electrolyte water solution, previously prepared, is pumped into the system taking advantage of the
circulating pumps already present in the system. Both reservoirs have an optical level indication and when the
filling level is reached, the operator stops the pumps and revert the opening of the filling tubes towards the
closed loop circuit.
As far as the electric circuit is closed, by a manual switch, the PVs starts delivering the BIAS voltage and the
system, provided that enough light radiation is present, start to electrolyze water. A visible amount of gas
bubbles is generated, as shown in the picture below, and the operator can activate the circulating pumps to
discharge the produced gas and free the electrodes to let them reach steady operation.
The volume of the liquid contained in the reservoirs allow operation of several hours before water refilling.
The visual inspection of the level allows the operator to know when the refilling is needed. In a future
industrial application, the refilling operation can be automated with a direct connection to water feeding
facility.
Revision: V1
Status: to be approved
7
Artiphyction – Project n. 303435
Deliverable 7000.7
2.2 Specifications
2.2.1 Solar irradiation specifications
The economic success of all solar applications that make use of solar radiation depends directly on the annual
amount of direct normal irradiation (DNI). In Europe the best sites are found in southern Spain (Figure 4a). For
this study the region of Seville is chosen as location and the data derived for the solar irradiation have been
1
extracted by the JRC Photovoltaic Geographical Information System .
(a)
(b)
Figure 4: (a) Daily direct irradiation on the Iberian peninsula. Seville is located in one of the regions of
highest insolation. Source: Soléner S.A., Madrid, Spain, (b) JRC Photovoltaic Geographical Information
System platform
The relevant geographic and environmental conditions for Seville are:
• Geographic position: 37° 24´N, 30 m above sea level.
• Visual range: 40 km
• Slope of land: horizontal
• Design point noon, June 21st
• DNI at design point 900 W/m²
• Annual sum of DNI Ea = 2015 kWh/m² (EC, 2005).
1
http://re.jrc.ec.europa.eu/pvgis/apps4/pvest.php?lang=en&map=europe
Revision: V1
Status: to be approved
8
Artiphyction – Project n. 303435
Deliverable 7000.7
• Air pressure and humidity are of no influence at this preliminary level.
Solar irradiation assumptions
The hydrogen yield has been calculated based on the current density produced at the ArtipHyction prototype
by the solar irradiation duration information given by the JRC Daily Ration Database. The current density was
2
2
assumed to be constant at 15 A/m , which corresponds to 0.56 g H2/m h production, when DNI at clear sky
2
exceeded 600 W/m , which varied from 6 to 12 hrs/day irradiation depending on the month.
2.2.2 Prototype production
The main parts of the PEC device are the anode production, the cathode production and the PEC assembly, as
shown in Figure 1 presenting the production process. A short description of its production step follows below.
POLITO prepared BiVO4 photo-anodes by means of an optimized technique able to increase the charge
transfer rate in the BiVO4 photo-electrodes through: a) Deposition of a co-catalyst (i.e. CoPi) and Mo-doping
of the BiVO4 film. The anodic photo-electrodes for the final Artiphyction prototype were prepared by the spincoating procedure, which allows a higher stability and reproducibility with respect to the other techniques
tested along the project. However, such procedure was further optimized in order to prepare bigger
2
2
electrodes than the originally tested within the WP2 (10 x 10 cm instead of 3 x 3 cm ). The final procedure
consist on the use of a solution of Bi(NO3)3 ∙5H2O and VO(AcAc)2 in Acetic Acid & Acetylacetone, with a
-1
concentration of both of 66 mmol.L . Proper amount of a Mo-precursor was used to achieve 3 mol% of Mo
dopant in the BiVO4 material. The spin-coating on FTO was optimized at a velocity of 250 rpm per 12 s, with a
subsequent deposition of 2 layers and final calcination of the film at 673 K per 2 h. Afterward, the CoPi cocatalyst was in-situ deposited on the BiVO4 surface during the prototype operation by adding 0.1mM of Conitrate in the Na-phosphate electrolyte solution. The performance of the large-scale electrodes was similar to
such of the small ones, under LSV analysis (I-V curves).
For the cathode electrodes, the cathode inks for each (10 cm  10 cm) size electrode were prepared using the
following formulation: 400 mg of catalyst (133.33 g Vulcan VXC72 and 266.66 g Co NPs), 2.75 ml of a 5 wt. %
Nafion® solution, 4.9 ml of ethanol and 1.2 ml of deionized water. This formulation corresponds to a Nafion®to-catalyst mass ratio of 0.3. The inks were sonicated for 1 h. Then, the catalysts inks were successively
deposited by spray coating technique (argon spray gun) on the microporous layer of an uncatalysed 100 cm
2
−2
gas diffusion layer (GDL, Sigracet 39-BC) to reach a catalyst loading of 4 mg·cm . For drying, the electrodes
were fixed on a hot plate at 80 °C under spraying.
Revision: V1
Status: to be approved
9
Artiphyction – Project n. 303435
Deliverable 7000.7
Due to some issues for the electrodeposition of the cathodic catalyst (Co-H2-Cat) on the large scale (10 x 10
2
cm ) electrodes, the Co-based cathodic electrodes were prepared at CEA facilities by ultrasonic spray-coating.
First, the Co catalyst was formulated: 216 g Co NPs, 108 g Vulcan VXC72 were suspended in 2.25 ml of a 5 wt.
% Nafion® solution, 4.9 ml of ethanol and 1.2 ml of deionized water. The mixture is sonicated for 1 h. Then,
the catalyst ink was deposited (deposition at 2 mL/min on a surface area of 9 cm x 9 cm) by ultrasonic spray
2
on the microporous layer of an uncatalysed 100 cm gas diffusion layer (GDL, Sigracet 39-BC) heated at 80°C.
−2
The catalyst loading is 4 mg·cm .
The key characteristics of the final prototype design are summarized in following:
•
A baffle in front of inlet channel helps electrolyte distribution on opposite sides of electrode. Inlet of
electrolyte flows in a collector chamber to keep down flow velocity. Each single inlet spot has a calculated
thru surface helping flatten differential pressure between each flow channel.
•
The distance between the active surfaces of the electrodes is about 7.5 millimeters, by using a Gas
Diffusion electrode in the cathodic side. This dimension takes in account mechanical manufacturing and
strength of structure.
•
Flow channels are machined in the width of diffuser layer and external frame needs to be strong
enough to compress gaskets throughout the system.
•
Assembly is a sandwich design cell with gaskets to avoid electrolyte/gas leakage. Correct amount of
compression is assured by 10 M5 A2 bolts treaded on PV frame steel inserts to avoid stripping of polymeric
material.
•
Activation of chemical reactions is made by a bias via photovoltaic (PV) cell system.
2.2.3 Energy Consumption and Raw Materials for prototype operation
The electrolyte is not consumed during the operation process; it should be prepared only at the first
operation day and water addition should be performed in order to maintain the original salts concentrations
in the system during operation.
Energy consumption
Machine
2 Electrolyte Pumps
Power
Time
0.18kW*2
1 hr
Price €
0.039
Raw materials
Raw Materials
Electrolyte (0.5mM Co(NO3)2.6H2O +
0.1M Sodium Phosphate)
Distilled water
Revision: V1
Quantity
Time
30 L
-
283
0.5 L
1 hrs
0.5
Status: to be approved
10
Artiphyction – Project n. 303435
Deliverable 7000.7
Figure 5: Energy consumption and raw materials for prototype operation
Upscale of the technology
2
Following the valuable experience carried out on the 1.6 m unit, an evolution of the design of a bigger
2
size unit is viable. A sustainable and logical upscale step will lead to a 10 m unit. PVs integration will be
more efficient and sensible surface saving will be addressed through an evolved design. The up scaled
unit will be automated to be water refilled when needed and completely power monitored per each
string. Produced gas collection and delivery will automatically drive the recirculation flow through a
devoted control loop. As a matter of fact, there is an optimal electrolyte flowrate to apply for every
working condition, where too low flowrate hamper the evolution of new gas bubbles, but too high
flowrate determine an energy wasting in the pumps.
2
It was assumed that the 10 m unit consist of 900 cells assembled in a square manner in a single module.
In this, the water flow is performed by 2 pumps powered directly by PV cells, with a consequent specific
power saving, which will be connected to a distilled water tank in order to automatically fill in the
system, in order to maintain its fully sustainability.
Table 1: Fixed cost evaluation for the two prototype cases
Fixed Costs (€)
1.6 m
1
2
3
4
Chemicals for synthesis
Consumables for synthesis
Energy consumption for synthesis and assembly
Electrolyte
Total
2
2
10 m industrially produced
7,263
960.14
34.67
283
8,541 €
993.59
993.59 €
The industrial costs for anode and cathode production have been evaluated according to current market
prices of glass substrates coated by similar materials and techniques. The PEC assembly cost was also
evaluated according to industrial scale supply of materials and energy resources that can be considered
when increasing the productivity by 1.000 times according to Hysytech’s experience (see Annex 1, Figure
16). The consumables and energy for the current case are included in the final market price.
Table 2: Operational cost evaluation for the two prototype cases
Operational Costs (€/day)
1.6 m
1
Distilled water
Total
Revision: V1
2
2
10 m industrially produced
0.005€
0.0045€
0.005€
0.0045€
Status: to be approved
11
Artiphyction – Project n. 303435
Deliverable 7000.7
3. Economic analysis
Figure 7 to Figure 14 in Annex 1 have provided the data for the calculation of the fixed costs shown in Figure
6, which derive from the materials and processes for the synthesis of 100 cells and their assembly in the 1.6
2
m PEC prototype. The materials and processes for the cell synthesis have been performed in lab-scale
equipment (POLITO, CEA), which required an increased consumption of energy and resources in contrast to
industrial production environments. Therefore, the highest amount of the Fixed Costs is attributed to the
chemicals for synthesis. This amount can be decreased when performing commercial production, in terms of
raw material supply and energy consumption.
Fixed Costs
Chemicals for synthesis
Consumables for synthesis
Energy consumption for synthesis and assembly
Electrolyte
Total
7263.3 €
960.1 €
34.6 €
283 €
8,541 €
2
Figure 6: Energy consumption and raw materials for 1.6 m prototype operation
2
Considering the 1.6 m pilot scale unit, the calculations led to the conclusion that the produced amount of H2
per year (PH2 = 3 kg/year) is not sufficient to implement an economic analysis based on the low operation
efficiency in combination with high fixed costs. The fixed costs (synthesis and assembly) are high, due to the
fact that these tasks were performed at different research and industrial facilities among the partners, as the
goal of the project was to achieve the successful production at pilot scale rather than to optimize the related
production costs.
2
On the other hand, an economic analysis was performed for a 10 m pilot scale unit taking into account cost
effective factors such as supply of chemicals and components in large scale and mass production of cells and
their assembly in an industrial environment [see Table 1, Figure 16]. Furthermore, the optimization of the
2
design to produce a 10 m prototype (such as increase of cells capacity and reduction of their number) gives
the potential to decrease the fixed cost to even lower values. The current calculations have been
implemented at different efficiencies from 5 to 10 %, values that have already been obtained at lab scale.
Nevertheless, further developments on photo- and electro-catalyst as well as on improved PEC design will
allow the increase of the efficiency at even higher values (up to 16 %).
The parameters and assumptions that were taken into account in the aforementioned analysis are the
following:
Revision: V1
Status: to be approved
12
Artiphyction – Project n. 303435



Process efficiency, n

Operational/depreciation time: N

H2 value: 5 €/kg

Annual income (S), €/yr:
Deliverable 7000.7
kg, where PH2 is the production rate (kg/yr)
Operational costs (C) are presented in Table 2






Fixed costs (IF) are presented in Table 1.
Annual gross profit R', €/yr:
(
)
∑
∑
(
(
)
)
Hydrogen production cost (HPC), €/kg:

Table 3 : Economic Analysis for based on the depreciation time of each efficiency
2

Economic Analysis for 10 m







n, %
N, yr
S, €/yr
HPC, €/kg
Production Rate, kg/yr
Efficiency
5
7
10
12
14
16
Depreciation Time
5
4
3
2
2
2
244
326
447
570
700
814
7.14
6.71
6.02
7.99
6.05
2.69
48.9
65.2
89.5
114
140
162.8
Table 3 depicts the economic factors based on the depreciation time for six different considered efficiencies
from 5 to 16 % (the depreciation time is the time calculated for the first positive Annual gross profit value).
The low 5 % efficiency needs 5 years of operation in order to depreciate both production and operational
costs, while a further increase of the efficiency over 10 % leads to 2 years’ depreciation time. The HPC value
though varies from 6.02 to 7.99 €/kg, supposing a efficiency lower than 14 % and depending on both the
depreciation time and the respective production rate per year. Surprisingly, the HPC can achieve 2.69 €/kg H2
with only 2 years of depreciation time if the efficiency rise up to 16 %, due to the increased H 2 production
rate. Obviously, the HPC will be further decreased when overcoming the depreciation time.

For such reason, the economic factors have also been calculated for two different depreciation times of N=3
2
years (Table 4) and N=5 years (Table 5), in order to show the potential Annual Gross Profit of the 10 m unit
when operating in periods overcoming that of the depreciation time. In such cases, the HPC reaches values
lower than 5 €/kg values (if the device efficiency is higher than 10%), thus making the Artiphyction technology
competitive in the current green H2 production market.
Revision: V1
Status: to be approved
13
Artiphyction – Project n. 303435
Deliverable 7000.7
Table 4: Economic Analysis for N=3 years depreciation time
2
Economic Analysis for 10 m
n (%)
Efficiency
5
7
10
12
14
16
S €/yr
HPC €/kg
244
326
447
570
700
814
11.03
8.27
6.02
4.73
3.85
3.31
Production Rate kg/yr
R’ €/yr
Annual Gross Profit
100
222
352
466
48.9
65.2
89.5
114
140
162.8
Table 5: Economic Analysis for N=5 years depreciation time
Economic Analysis for 10 m
2
n (%)
S €/yr
HPC €/kg
Production Rate kg/yr
Efficiency
5
7
10
12
14
16
244
326
447
570
700
814
7.14
5.35
3.9
3.06
2.49
2.14
48.9
65.2
89.5
114
140
162.8
R’ €/yr
Annual Gross Profit
29
110
232
355
485
599
The current result of the ArtipHyction project is well in agreement with the analysis depicted in the “Study on
hydrogen from renewable resources in the EU” by Ludwig-Boelkow-Systemtechnik GmbH, where an Hydrogen
Production Cost Ex Plant is addressed as 4.82 €/kgH2 (see CAPEX + OPEX of Central PEC in figure below).
ArtipHyction (PEC)
Hydrogen Production Cost Range
2
(CAPEX and OPEX for 10 m )
Revision: V1
Status: to be approved
14
Artiphyction – Project n. 303435
Deliverable 7000.7
Costs of hydrogen production range from PEC ‘well-to-tank’ compared to hydrogen from SMR and water electrolysis (left
2
table from Ludwig-Boelkow-Systemtechnik GmbH) and blue arrow from ArtipHyction projection of 10 m unit based on
2
demonstration of 1.6 m prototype.
Is worth of notice that materials of ArtipHyction anodes and cathode have a major influence on the efficiency
and cell lifetime. The choice in the ArthipHyction development, as described in the D7.5, was to mitigate the
stressed conditions of the maximum efficiency working point operating at a lower current density, in favour of
a prolonged lifetime of the cells.
Due to the relatively low efficiency large scale PEC hydrogen production will demand vast areas for collecting
the necessary solar power, potentially leading to significant capital costs. Additionally, it will require large
amounts of non-active materials associated to the panel reactor (plastic, glass, pipes to collect the hydrogen
generated, etc.) and high installation costs (cabling, piping, mount-structures, etc.). Therefore, maximizing the
conversion efficiency in order to reduce the overall footprint remains a critical factor for reducing the H2
production costs.
Hence, the future steps will be focused on the reduction of production cost, through the evolution of
materials and design for increasing lifetime and stability. BoP components has to be designed and optimized
for large scale applications. Potential of sunlight concentration needs further investigation, where a probable
result would be a decreasing of the specific amount of anode and cathode materials, with an overall capital
cost reduction. Indeed, the circulating fluid electrolyte system is already suitable for thermal stabilization of
the system, through heat exchangers integration. The possible drawback of lifetime reduction can be
mitigated with an appropriate material selection and a proper coupling with the actual most cost-effective PV
devices. Since the design of PEC device prototypes is closely interlinked with the photo-active and auxiliary
materials used, addressing fundamental research on materials, in parallel with applied engineering research
on device design and integration, seems necessary to develop optimized systems that can reach the desired
hydrogen production cost targets.
Revision: V1
Status: to be approved
15
Artiphyction – Project n. 303435
4.
Deliverable 7000.7
Conclusion
The time has indeed come to establish an extensive research effort to develop concepts and technologies to
exploit the enormous amount of solar energy, which falls on our planet. The annual global energy
consumption rate at present is about 16 TW and will rise towards 20 TW within this decade. The energy
provided by solar radiation is over 100,000 TW. At present about 11 % of global fuel demand comes from
biomass (combustion and fermentation) while 85% is derived from fossil fuels. In terms of solar energy
conversion, the early stages of photosynthesis, including the water splitting reaction, are highly efficient,
while the production of biomass is much less so. The ArtipHyction (PEC) technology is aimed at carrying out
water splitting to get directly purified H2 in an intensified system compared to that taking place naturally in
algae and, therefore, has the potential to solve the problem of energy procurement of mankind and to have
an impact much broader than those hypothesised now for biofuels.
The ArtipHyction project let the FCH JU initiative become a key player in the worldwide PEC R&D context. For
this reason, a Science Policy Brief was produced by a consortium of European Scientists, for the European
Science Foundation entitled “Harnessing Solar Energy for the Production of Clean Fuel”. The mission of the
ArtipHyction project followed this path by gathering together scientists with clear expertise and a wide former
cooperation record from the fields of physical chemistry, organic chemistry, biochemistry, molecular biology,
material sciences and chemical engineering. Coupled to this interdisciplinary team is the involvement of hightechnology SMEs selected for their unique capabilities and strong commitment.
In line with the reference Annual Implementation Plan of the FCH JU, the Artiphyction concept is a promising
sustainable technology for the production of green H2 at low temperatures where the whole production chain
is limited in a PEC cell, which on the one hand collects the sunlight and on the other hand produces in situ
continuous hydrogen and oxygen. The project has successfully implemented the scale up of the technology
2
2
from a 1.5 cm (of photoactive area) in a lab-scale cell to the 1.6 m prototype, overcoming the drawbacks
and collecting experience from four successive dimension upgrades. Nevertheless, high troubles were faced
for the scale up of the lab results, regarding mostly the electrodes performance and the device design.
2
Therefore, even though efficiencies as high as 5% have been achieved with small photo-electrodes (1.5 cm of
2
photoactive area) in lab tests, the scale-up of the electrodes (each of 64 cm of photo-active area) induces
additional losses that compromise their efficiency. Moreover, in the final device the efficiency must account
not only the photoactive area, but the actual area covered by the prototype, and such leads to a decrease in
about a half of the overall current density values. For such reason, as well as due to the choice of mitigate the
stressed conditions of the maximum efficiency working point operating at a lower current density in favour of
a prolonged lifetime of the cells, the final Artiphyction prototype worked with an efficiency of about 1%
(producing 1 g/h H2), with a proved stability of 1.000 h.
Revision: V1
Status: to be approved
16
Artiphyction – Project n. 303435
Deliverable 7000.7
Furthermore, the project achieved a significant result in term of demonstration at practical application size
2
(1.6 m ), bringing out of the labs the technology to be evaluated in real environment. As natural, several
opportunities to increase performance and, most of others, to drastically reduce the production cost were
advised from a complete techno-economic analysis of the developed technology. The chance to enlarge the
size of the prototype unit, and consequently increase the production volumes of cells and panels, will
generate more experience and will drive the cost reduction, taking advantage of bigger purchasing and
serialised machining and operation.
Overall, the main objective of future exploitation works after the completion of the ArtipHyction project is to
create a significant and practical PEC technology in the medium long term, to create awareness of its potential
benefits, to assess how the reduction of the production cost versus the increase on production volumes can
facilitate the profitability of large-scale sun-driven H2 production. From the previously presented analysis, a
2
scale up to 10 m of the PEC device is practically the next step that should be followed, in order to render
economically feasible the H2 production with the photo-electrochemical technology used in the Artiphyction
project. Obviously, more efforts are necessary to increase the current efficiencies at values higher than 5 %.
From the analysis made based on the Artiphyction prototype, the H2 production cost can reach lower values
than 5 €/kg in less than 5 years, if the device efficiency is higher than 10% (while for lower efficiency values
the fixed costs must be drastically reduced), thus making the Artiphyction technology competitive in the
current green H2 production market.
With a solar light to hydrogen conversion efficiency of 10 % and an average solar radiation input of 1000 kWh
2
per m in Europe, one gets 3 kg of solar H2 per year per m2 of exposed PEC converter surface. If a 7 €/kg cost
of solar-electrolytic hydrogen is considered, each single panel will provide an equivalent H2 value of about 24
2
€/m /yr. Assuming a lifetime of 20 years of the ArtipHyction panels (i.e. a depreciation of 5 % p.a.), and a
2
money capitalization of 5 %, one can afford costs lower than 200 €/m of the ArtipHyction panels including
the installation.
2
When comparing the projected dye solar cell module costs of ~ 80 € / m (taken on a 20 MWp/year we may
2
2
assume that the ArtipHyction panels could cost no more than 100 € /m , still leaving up to 100 € /m for
installation and hydrogen handling.
With scaling-up and the rational production of the hydrogen handling parts, overall costs of less than 100 €
2
per installed m are achievable, opening a huge market of clean hydrogen fuel, being cheaper than today’s
fossil fuels. PEC technology can generally produce hydrogen in local, semi-central, and central settings and has
a chance to reach hydrogen production costs levels comparable to water electrolysis and steam methane
reforming by 2030.
Revision: V1
Status: to be approved
17
Artiphyction – Project n. 303435
Deliverable 7000.7
As described in the “Study on hydrogen from renewable resources in the EU” by Ludwig-BoelkowSystemtechnik GmbH, PEC technologies need to increase experience on larger-scale system, to increase the
actual TRL to better compete and potentially win the race for an affordable Hydrogen Production Cost with
renewable energy. The Artiphyction project achieved indeed for the first time a (previously missing)
2
demonstration of H2 production in a scaled-up pilot system (i.e. 1.6 m ) that correspond to a TRL 5 for the PEC
technology.
The next table present the gaps analysis summary benchmarking the key performance indicators (KPI) of six
selected pathways from the above mentioned study, against water electrolysis (WE) and steam methane
reforming (SMR) for the reference year 2030 (Summary of gaps analysis – Comparison of key performance
indicators (KPIs) of selected Pathways to benchmark technologies). From the figure below, it is possible to see
how the scale-up of the Artiphyction technology (and a consequent improvement on efficiency, optimized
materials, reactor design, lifetime, cost-reduction, integration with another devices such as PV or
concentrated PV cells, etc) can lead to the improvement of the most critical key performance indicators of the
PEC technology (i.e. TRL and H2 cost).
++
+
Revision: V1
much better than benchmark (SMR and water electrolysis)
better than benchmark (SMR and water electrolysis)
Status: to be approved
18
Artiphyction – Project n. 303435
Deliverable 7000.7
0
--
similar performance as benchmark
worse than benchmark
much worse than benchmark
WE: water electrolysis using renewable electricity (solar); SMR: steam methane reforming; n. a.: not applicable
The PEC technology offers one of the most interesting (and challenging) pathways for hydrogen production as
it offers the theoretical prospect of being only slightly more complex than pure PV technology at only
marginally higher cost. The long-term target for the PEC hydrogen production pathway is to reach efficiencies
comparable to those of PV combined with electrolysis using cost competitive materials. Hence, research
should aim to achieve solar-to-hydrogen efficiencies in the range of at least 10% to 12% while ensuring device
stability and minimum degradation for a period of at least 10 years. Those conditions could lead to hydrogen
production costs in the range of 4-5 €/kgH2 by 2030. R&D efforts should focus on materials development,
along with reactor design and engineering. The work should be directed to improve the device efficiency and
durability, while increasing systems size and decreasing its costs.
Revision: V1
Status: to be approved
19
Artiphyction – Project n. 303435
Deliverable 7000.7
ANNEX I
2
Technical basis and respective cost for 1.6 m prototype
2
2
The 1.6 m Artiphyction prototype, consisting of 100 (10x10 cm ) cells was fully developed at the lab facilities
of POLITO (anode) and CEA (cathode), while the PEC assembly was performed at the Hysystech industrial
environment. The raw materials supply was therefore performed at low quantities for lab-use, fact that
contributes to the high value of the Fixed Costs at such scale.
Anode Production (20 electrodes)
Raw Materials
BiNO3.5H2O powder
VO(AcAc)2 powder
MoO2(AcAc)2 powder
CH3COOH
Acetylacetone
FTO-covered borosilicate
glass
Na2HPO4.2H2O
NaH2PO4.H2O
Co(NO3)2.6H2O
Quantity
16.5 g
3.2 g
0.065 g
16.5 ml
83.5 ml
100 cm
2
2.6176 g
1.8624 g
0.928 g
Company
Sigma Aldrich
Sigma Aldrich
Sigma Aldrich
Sigma Aldrich
Sigma Aldrich
Price €
Sigma Aldrich
9.20
10.52
6.04
0.24
3.65
11.02
Sigma Aldrich
Sigma Aldrich
Sigma Aldrich
0.83
1.29
14.19
57 €
Total 20 electrodes
Total 100 electrodes 285 €
Figure 7: Raw materials and respective price for anode production
Anode Production (20 electrodes)
Raw Materials
Water
Distilled water
Bidistilled water
H2SO4
H2O2
Acetone
Ethanol
Paper
Plastic Tape
1 Ag/AgCl electrode
1 Pt wire
Quantity
Price €
0.001
0.1
0.5
16.3
11.7
2.1
3.7
0.002
0.002
77
3
0.04 cm
240
Total 20 electrodes
34 €
487 €
Total 100 electrodes
4000 ml
110 ml
100 ml
187.5 ml
62.5 ml
50 ml
70 ml
2
1800 cm
2
10 cm
Figure 8: Consumables and respective price for anode production
Revision: V1
Status: to be approved
20
Artiphyction – Project n. 303435
Deliverable 7000.7
Anode Production (20 electrodes)
Raw Materials
Ultrasound Bath
Magnetic Stirrer
Hot plate
Vacuum pump
Spin coater
Potentiostat
Lamp
Computer
Furnace
Balance
Power
Time
Price €
6h
0.18
6h
0.29
200 min
0.29
20 min
0.012
20 min
0.018
60 min
0.055
20 min
0.012
20 min
0.001
310 min
3.97
20 min
0.0047
Total 20 electrodes 4.86 €
Total 100 electrodes 24.3 €
285 W
450 W
800 W
350 W
500 W
500 W
350 W
7 kW
130 W
Figure 9: Energy consumption for synthesis and respective price for anode production
Cathode Production (10 electrodes)
Raw Materials
Co nanoparticles powder
Carbon black Vulcan VXC72
SIGRACET GDL 39 BC
Nafion 117 solution
Quantity
Company
2.16 g
1.08 g
2
100 cm
22.5 ml
Alfa Aesar
Cabot
SGL Carbon Group
Sigma Aldrich
Total 10 electrodes
Total 100 electrodes
Price €
134.5
1.01
3.7
42.2
181.5 €
1815 €
Figure 10: Raw materials and respective price for cathode production
Cathode Production (10 electrodes)
Raw Materials
Distilled water
Ethanol
Quantity
Price €
12.5 ml
0.02
50 ml
0.163
Total 20 electrodes 1.83 €
Total 100 electrodes 18.3 €
Figure 11: Consumables and respective price for cathode production
Cathode Production (10 electrodes)
Raw Materials
Ultrasound Bath
Hot plate
Revision: V1
Power
285 W
800 W
Time
Price €
5 hrs
0.15
150 m
0.22
Total 20 electrodes 0.37 €
Total 100 electrodes 3.7 €
Status: to be approved
21
Artiphyction – Project n. 303435
Deliverable 7000.7
Figure 12: Energy consumption for synthesis and respective price for cathode production
PEC Assembly (5 cells)
Raw Materials
Photovoltaics
PVC
Si gasket
Quantity
Country
171 cm
2337 gr
2
1000 cm
China
Italy
Italy
Total 5 cells
Total 100 cells
2
Price €
14.92
238.26
5
258 €
5164 €
Figure 13: Raw materials and respective price for PEC Assembly
PEC Assembly
Raw Materials
Quantity
Liquid Cleaner
Pumps
Price €
10 ml
2
Total
1
454.2
455.2 €
Figure 14: Consumables and respective price for PEC Assembly
PEC Assembly (5 cells)
Raw Materials
Electric
screwdriver
rotation 2 rpm for
10 min
CNC Milling
Machine
Power
Time
1.5 kW
30 sec
Price €
0.08
1.5 kW
90 min
0.24
Total 5 cells 0.33 €
Total 100 cells 6.6 €
Figure 15: Energy consumption and respective price for PEC Assembly
Revision: V1
Status: to be approved
22
Artiphyction – Project n. 303435
Deliverable 7000.7
2
Technical basis and respective cost for 10 m prototype
2
The Economic analysis performed for the 10 m unit, consisting of 900 cells was based on the prices obtained
2
for large scale material supply, which from an initial estimation reduces the production cost per m by at least
85 %. Moreover, an ab initio design of the PEC and its production at industrial scale could reduce the
2
production costs at ~100 €/m , as well as more developments on the design (i.e. by increasing the cell
dimensions and decreasing the cells number) has the potential of decreasing even further the production
cost. Manufacturing processes for industrial ArtipHyction production will follow also the recent development
of the PV printing, allowing a realistic cost reduction due to lighter process. The projection of the production
costs considering such factors were calculated and are summarised hereafter.
Anode
Production
Anode
Catalyst and
FTO covered
borosilicate
glass
Cathode
Production
Cathode
catalyst
covered
substrate
PEC Assembly
Price
(Euro)
0.4
Price
(Euro)
Unit
Quantity
for 20
electrode
Unit
100
2
cm
2000.00
cm
Quantity
for 20
Unit
Unit
2
Price
(Euro)
Price (Euro)
2
for 10 m
900
360.00
Quantity for
Price (Euro)
2
electrode
0.26
Quantity for
2
10 m
100
cm
2
Unit
2
Photovoltaics
0.0075
cm
PVC
0.000715
gr
Si gasket
0.00002225
cm
2
2000.00
Quantity
for 5 cells
2
10 m
cm
2
Unit
171.00
cm
1280.00
gr
1000.00
cm
Total for 10 m
for 10 m
2
2
900
234.00
Quantity for
2
10 m
Price (Euro)
2
for 10 m
30780
230.85
230400
164.74
180000
4.01
2
993.59 €
Figure 16: Cost of industrial scale production of anode and cathode electrodes and PEC assembly
2
corresponding to a 10 m unit.
Revision: V1
Status: to be approved
23