HPQ Silicon advances its plasma-based quartz-to-fumed-silica process with successful Test #7, nearing premium-grade material production and commercial scalability.
HPQ Silicon Inc., a leading innovator in advanced materials and sustainable process technologies, has announced the successful completion of Test Series #7 at its proprietary Fumed Silica Reactor (FSR) pilot plant. The pilot facility, operated by HPQ’s wholly owned subsidiary HPQ Silica Polvere Inc. (HSPI) and developed in collaboration with engineering partner PyroGenesis Inc., represents another significant advancement in the company’s quest to commercialize a direct-quartz-to-fumed-silica manufacturing process.
This breakthrough approach eliminates the need for multiple costly intermediate steps that typically define conventional production routes. Instead, HPQ’s plasma-based reactor directly transforms quartz into fumed silica—an essential, high-value material used across diverse industries, including electronics, batteries, cosmetics, and sealants. The process is not only designed to cut energy consumption and carbon emissions drastically but also aims to establish a more efficient and sustainable production chain.
Bernard Tourillon, President and CEO of HPQ Silicon Inc. and HPQ Silica Polvere Inc., expressed optimism about the results, stating, “Each completed test moves us closer to demonstrating that low-energy, low-carbon, direct-from-quartz fumed silica can be produced reliably and competitively. These achievements validate years of dedicated R&D investment and showcase the scalability of our proprietary technology.”
Before the initiation of Test Series #7, PyroGenesis implemented two major engineering improvements to optimize reactor performance. The first enhancement targeted an increase in the surface area of the fumed silica, a critical metric for product quality and commercial competitiveness. Earlier test series have shown consistent progress, improving from 28 m²/g in Test #4, to 44 m²/g in Test #5, and 136 m²/g in Test #6. With the latest engineering adjustments, the goal for Test Series #7 was to achieve a surface area exceeding 150 m²/g, aligning with industry benchmarks for premium-grade fumed silica, which typically range between 150 and 200 m²/g.
The second improvement prepared the FSR pilot system for extended multi-day continuous operations, a key milestone for industrial-scale validation. The current production target is 200 kilograms of fumed silica, intended for distribution to potential customers under non-disclosure agreements for independent evaluation. Samples from this batch have been dispatched to an accredited third-party laboratory for certification testing, with official results anticipated within ten business days.
Tourillon added that the upcoming Test Cycle #8 will build on these results to pursue the next-generation fumed silica grades, aiming for surface areas of up to 300 m²/g. “We are progressing from proof-of-concept toward commercial validation,” he noted, “positioning HPQ to deliver low-energy, high-value materials that reinforce North America’s supply chain resilience while meeting global market standards.”
