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.
