Levelized Cost and Carbon Intensity of Solar Hydrogen Production from Water Electrolysis Using a Scalable and Intrinsically Safe Photocatalytic Z-Scheme Raceway System
Authors: Acevedo Yaset , Collins Stephanie , Esposito Daniel V. , Bala Chandran Rohini , Ardo Shane , Breunig Hanna , James Brian 
Published: August 2024

The realization of an environmentally sustainable and widely-adopted hydrogen economy may require lowering hydrogen production costs of production pathways with ultra-low greenhouse gas emissions to $1/kg H2. The allocation of new or existing renewable electricity generation solely to hydrogen production remains contentious due to disputes regarding emissions accounting. Photoelectrochemical (PEC) hydrogen production technologies offer a unique solution, as hydrogen is produced directly from solar energy and water, without the need for electricity generation. However, cost projections for past photoelectrochemical designs have suggested that they are not cost competitive compared to conventional electrolysis systems manufactured at scale. Herein, we offer the first illustrative benchmark of cost and carbon intensity of hydrogen produced in a Type 2 Z-scheme photocatalytic reactor design that employs suspended semiconducting nanoparticles organized in two stacked baggies in a raceway design.

To explore the near-term and future cost projection for hydrogen production via Type 2 photocatalytic Z-scheme raceways, the authors developed a bottom-up total installed capital cost model. This project cost model incorporates: 1) raceway reactor cost, derived from a Design for Manufacturing and Assembly (DFMA) process-based cost model, 2) mechanical balance of plant, including process equipment, piping, valves, and instrumentation, derived from equipment quotes, scaling, database values, and Aspen estimates; 3) electrical balance of plant, including wiring, derived from time and material cost correlations; 4) Site Preparation, focused on green field installation; and 5) Construction Overhead, including engineering, procurement, and construction (EPC) costs and project contingency. The capital cost model is fed into a Levelized Cost of Hydrogen (LCOH) discounted cash flow model that accounts for electricity and water consumption, in addition to other operating costs, including labor, maintenance, and raceway replacements.

A hybrid life-cycle approach was used to develop an inventory of greenhouse gas emissions from all materials and energy flows associated with the facility life cycle. These flows are converted to emissions based on specific emission factors, or by using physical units-based input–output LCA models associated with the broader economic impacts of fuel and materials production, use, and end use.

Estimates for levelized cost of hydrogen suggest that a 50 metric ton H2 per day (MTD) raceway plant can approach $2.50/kg H2 at an 8% solar-to-hydrogen efficiency with further cost improvements possible through increased performance and larger plant scales. Carbon intensity is estimated to be well under clean hydrogen targets for global warming potential of <2-4 kg CO2e/kg H2 produced. The results suggest a highly competitive and scalable technology, that justifies further experimental validation and prototyping in the field.

Figure 1