HPQ’s plasma-based fumed silica pilot achieves lab-quality results, advancing toward commercial viability with cleaner, scalable, and efficient production methods.
HPQ Silicon Inc., a leader in advanced material innovation and process development, has shared a significant update on the ongoing progress of its Fumed Silica Reactor (FSR) pilot project. This initiative, developed in collaboration with PyroGenesis Inc., is moving closer to commercial viability. Following its July 3rd announcement, HPQ has now obtained an independent Scanning Electron Microscope (SEM) analysis of the materials produced during Phase 1 Tests #4 and #5, offering promising insights into the performance of the pilot-scale system.
The SEM evaluation, conducted by an independent laboratory and assessed by PyroGenesis, confirmed that the materials produced during Test #5 of HPQ Silica Polvere Inc. (HSPI)’s pilot-scale reactor displayed structural features consistent with high-quality, commercial-grade fumed silica that had previously only been achieved in lab-scale experiments. Furthermore, the SEM analysis highlighted significant improvements in particle morphology and consistency, particularly following process enhancements implemented after Test #4. Notably, the current reactor output is showing potential to replicate the specific surface area metrics typically achieved in lab-scale production, a critical quality factor in commercial-grade fumed silica.
This milestone underscores HPQ’s transition from experimental laboratory production to reliable, semi-continuous pilot-scale manufacturing. According to Bernard Tourillon, President and CEO of HPQ Silicon and HPQ Silica Polvere Inc., the SEM findings validate the scalability of the FSR technology. "These results confirm we’re not only maintaining lab-quality characteristics at scale, but also improving overall process control and product uniformity," Tourillon noted. "With this foundation, we are now well-positioned for Phase 2 testing, which will further advance our efforts to outperform conventional commercial-grade fumed silica—environmentally and economically."
Looking ahead, Phase 2 of the pilot project is scheduled to begin in early August 2025. The primary goal will be to consistently reproduce the surface area characteristics achieved at the lab level, ensuring the product meets the rigorous standards of potential commercial partners. Success in this phase will enable HPQ to move forward with sample qualification programs and continue negotiations with prospective off-takers.
The broader vision of the FSR project is to develop a next-generation, environmentally responsible method of producing fumed silica. Traditional production methods involve high-temperature flame hydrolysis using silicon tetrachloride (SiCl4), a process that releases substantial CO2 and hazardous chlorine compounds. HPQ’s innovative plasma-based process instead uses quartz as the feedstock, eliminating harmful reagents and significantly lowering environmental impact.
With the global fumed silica market projected to grow to US$3.54 billion by 2029 at a CAGR of 7.46%, HPQ’s process stands out as a scalable, cost-effective, and cleaner alternative. Applications in batteries, construction, sealants, and cosmetics could all benefit from this sustainable advancement.
