Periodic Reporting for period 3 - ColdSpark (COLDSPARK DRIVEN ENERGY AND COST-EFFICIENT METHANE CRACKING FOR HYDROGEN PRODUCTION)
Reporting period: 2024-12-01 to 2025-11-30
Europe urgently needs to decarbonise hydrogen production while maintaining energy security, industrial competitiveness, and strategic autonomy. Over 95% of EU hydrogen is still fossil based via SMR, generating high CO2 emissions and exposing industry to volatile gas prices. The EU is also dependent on non EU suppliers for critical carbon materials used in mobility, energy storage, chemicals, and advanced manufacturing.
ColdSpark® addresses this gap by providing a scalable, low temperature technology that converts methane—including biomethane—into clean hydrogen and high value solid carbon without CO2 emissions, catalysts, or critical raw materials. The project aligns with the European Green Deal, Fit for 55, REPowerEU, the EU Hydrogen Strategy, and the Critical Raw Materials Act by reducing emissions, valorising methane streams, diversifying hydrogen pathways, and strengthening EU materials autonomy.
ColdSpark® validated a novel non thermal plasma methane splitting process at lab and pilot scale, demonstrating high methane conversion, hydrogen and solid carbon co production, validated reactor and HVPS components, industrially relevant eCarbon®, and TRL 5 readiness.
Designed as the first step toward deployment, ColdSpark® supports climate goals through CO2 free hydrogen, industrial needs through modular decentralised production, and strategic needs through EU-based carbon materials. At scale, it can cut lifecycle emissions by >60% vs SMR, complement electrolysis, enable circular biogas models, and reinforce EU strategic autonomy.
ColdSpark® addresses this gap by providing a scalable, low temperature technology that converts methane—including biomethane—into clean hydrogen and high value solid carbon without CO2 emissions, catalysts, or critical raw materials. The project aligns with the European Green Deal, Fit for 55, REPowerEU, the EU Hydrogen Strategy, and the Critical Raw Materials Act by reducing emissions, valorising methane streams, diversifying hydrogen pathways, and strengthening EU materials autonomy.
ColdSpark® validated a novel non thermal plasma methane splitting process at lab and pilot scale, demonstrating high methane conversion, hydrogen and solid carbon co production, validated reactor and HVPS components, industrially relevant eCarbon®, and TRL 5 readiness.
Designed as the first step toward deployment, ColdSpark® supports climate goals through CO2 free hydrogen, industrial needs through modular decentralised production, and strategic needs through EU-based carbon materials. At scale, it can cut lifecycle emissions by >60% vs SMR, complement electrolysis, enable circular biogas models, and reinforce EU strategic autonomy.
Technical and Scientific Activities Performed and Main Achievements
ColdSpark® advanced non-thermal plasma (NTP) methane splitting through integrated reactor development, plasma optimisation, carbon product characterisation, and demonstration of hydrogen–carbon co–production. These efforts strengthened the scientific foundation and technological readiness of the ColdSpark® process.
The project developed a fully integrated ColdSpark® reactor system featuring an optimised plasma chamber, custom high voltage power supply, and carbon handling subsystems. Bench scale testing confirmed stable plasma ignition, effective thermal management, and reliable continuous methane conversion, establishing a robust platform for optimisation.
Systematic studies of voltage, pulse frequency, and residence time clarified their influence on methane conversion, carbon formation, and product purity. These experiments improved control over decomposition pathways, enhanced process stability, and generated datasets supporting scale- up and control strategies.
The reactor successfully produced high- purity filamentous carbon across multiple operating regimes. The collected materials formed a representative dataset for structure–property analysis and demonstrated the technology’s ability to generate valuable carbon co- products without catalysts or high temperatures.
SEM, TEM, Raman spectroscopy, XRD, and elemental analysis confirmed the morphology, microstructure, crystallinity, and purity of the carbon products. Results showed that plasma parameters can systematically tune carbon structure, highlighting the process’s potential for tailored, application-specific materials.
No CO2 or CO formation was detected, validating the carbon-neutral reaction pathway and confirming the core ColdSpark® value proposition.
Plasma and reaction dynamics models provided predictive insight into energy distribution, species formation, and plasma–gas interactions. These tools guided experimental design, supported optimisation, and reduced uncertainty for future scale-up.
By the end of the reporting period, ColdSpark® had validated its integrated reactor system, demonstrated stable CO2-free hydrogen and carbon co- production, and achieved controlled tuning of carbon morphology. These achievements significantly advance the technology toward continuous operation and industrial demonstration.
ColdSpark® advanced non-thermal plasma (NTP) methane splitting through integrated reactor development, plasma optimisation, carbon product characterisation, and demonstration of hydrogen–carbon co–production. These efforts strengthened the scientific foundation and technological readiness of the ColdSpark® process.
The project developed a fully integrated ColdSpark® reactor system featuring an optimised plasma chamber, custom high voltage power supply, and carbon handling subsystems. Bench scale testing confirmed stable plasma ignition, effective thermal management, and reliable continuous methane conversion, establishing a robust platform for optimisation.
Systematic studies of voltage, pulse frequency, and residence time clarified their influence on methane conversion, carbon formation, and product purity. These experiments improved control over decomposition pathways, enhanced process stability, and generated datasets supporting scale- up and control strategies.
The reactor successfully produced high- purity filamentous carbon across multiple operating regimes. The collected materials formed a representative dataset for structure–property analysis and demonstrated the technology’s ability to generate valuable carbon co- products without catalysts or high temperatures.
SEM, TEM, Raman spectroscopy, XRD, and elemental analysis confirmed the morphology, microstructure, crystallinity, and purity of the carbon products. Results showed that plasma parameters can systematically tune carbon structure, highlighting the process’s potential for tailored, application-specific materials.
No CO2 or CO formation was detected, validating the carbon-neutral reaction pathway and confirming the core ColdSpark® value proposition.
Plasma and reaction dynamics models provided predictive insight into energy distribution, species formation, and plasma–gas interactions. These tools guided experimental design, supported optimisation, and reduced uncertainty for future scale-up.
By the end of the reporting period, ColdSpark® had validated its integrated reactor system, demonstrated stable CO2-free hydrogen and carbon co- production, and achieved controlled tuning of carbon morphology. These achievements significantly advance the technology toward continuous operation and industrial demonstration.
ColdSpark® demonstrated the feasibility of NTP methane splitting as a carbon- neutral route to hydrogen and solid carbon. Major results include:
• Integrated plasma reactor validation with no CO2 emissions.
• Custom high voltage pulsed power supply providing precise plasma control and improved energy efficiency.
• Co- production of hydrogen and high- purity carbon filaments with reproducible morphology.
• Tunable carbon properties through plasma parameter adjustment, enabling high- value carbon products.
• Modular, containerised system operation suitable for decentralised hydrogen production.
• Operational flexibility, including stable start- stop cycling for variable energy or feedstock conditions.
These achievements significantly advance ColdSpark® toward industrial readiness.
Scientific, Technological, and Industrial Impacts
1. The project confirmed controlled, high- purity carbon filament synthesis, positioning ColdSpark® as both a hydrogen and carbon materials platform. Carbon’s ease of storage and transport strengthens early commercial potential.
2. The custom HV pulsed supply ensures stable plasma behaviour, efficient energy transfer, and reproducible operation—critical for both hydrogen yield and carbon quality.
3. Strong potential for carbon optimised operation, with hydrogen used locally and carbon transported as the primary value stream.
4. Validated architecture supports on- site use at methane or biogas sources, reducing infrastructure needs and enabling phased scale-up.
5. Robust start-stop capability supports integration with renewables and variable biogas, offering advantages over high- temperature reforming.
Key Needs for Further Uptake
1. Expanded safety and operational research, including hydrogen safety, carbon handling, and large- scale HAZOP/LOPA studies.
2. Optimisation of operating windows for yield, carbon quality, efficiency, and system lifetime.
3. Dedicated carbon product development covering qualification, standardisation, and application testing.
4. Higher TRL demonstration at increased power and duration to reduce scale-up risk.
5. Market, finance, and IPR support to secure investment and early partnerships.
6. Regulatory and standardisation engagement for carbon classification and decentralised hydrogen permitting.
• Integrated plasma reactor validation with no CO2 emissions.
• Custom high voltage pulsed power supply providing precise plasma control and improved energy efficiency.
• Co- production of hydrogen and high- purity carbon filaments with reproducible morphology.
• Tunable carbon properties through plasma parameter adjustment, enabling high- value carbon products.
• Modular, containerised system operation suitable for decentralised hydrogen production.
• Operational flexibility, including stable start- stop cycling for variable energy or feedstock conditions.
These achievements significantly advance ColdSpark® toward industrial readiness.
Scientific, Technological, and Industrial Impacts
1. The project confirmed controlled, high- purity carbon filament synthesis, positioning ColdSpark® as both a hydrogen and carbon materials platform. Carbon’s ease of storage and transport strengthens early commercial potential.
2. The custom HV pulsed supply ensures stable plasma behaviour, efficient energy transfer, and reproducible operation—critical for both hydrogen yield and carbon quality.
3. Strong potential for carbon optimised operation, with hydrogen used locally and carbon transported as the primary value stream.
4. Validated architecture supports on- site use at methane or biogas sources, reducing infrastructure needs and enabling phased scale-up.
5. Robust start-stop capability supports integration with renewables and variable biogas, offering advantages over high- temperature reforming.
Key Needs for Further Uptake
1. Expanded safety and operational research, including hydrogen safety, carbon handling, and large- scale HAZOP/LOPA studies.
2. Optimisation of operating windows for yield, carbon quality, efficiency, and system lifetime.
3. Dedicated carbon product development covering qualification, standardisation, and application testing.
4. Higher TRL demonstration at increased power and duration to reduce scale-up risk.
5. Market, finance, and IPR support to secure investment and early partnerships.
6. Regulatory and standardisation engagement for carbon classification and decentralised hydrogen permitting.