PyroGenesis enhances fumed silica quality and purity, achieving commercial-grade output through reactor upgrades and sustainable, hydrochloric-acid-free production.
PyroGenesis Inc., a Canadian high-tech company specializing in plasma-based processes and sustainable industrial solutions, has announced significant progress in its fumed silica reactor (FSR) project. The company revealed that the latest round of optimization testing has delivered substantial improvements in the quality, purity, and consistency of fumed silica production over several production cycles. These advancements were achieved as part of PyroGenesis’ collaborative project with HPQ Silicon Inc. and its subsidiary HPQ Polvere Inc., for which PyroGenesis is responsible for the development and construction of the FSR pilot plant.
Under a joint venture agreement, PyroGenesis holds a 50% ownership stake in HPQ Polvere and retains exclusive rights as the sole equipment provider for any future commercialization of the technology. The project has been progressing through a series of testing phases, transitioning from laboratory to pilot scale, with the goal of scaling production while preserving material quality. These phases include key system modifications and iterative refinements to improve output metrics.
The most recent testing phase, conducted as part of a planned optimization cycle, produced several notable outcomes. These include an 86% reduction in impurities, an 85% decrease in carbon presence, consistent product properties across multiple production batches, the introduction of a semi-continuous raw material feed system, and a 57% increase in the surface area of the fumed silica. The latter is particularly critical because larger surface areas are required for fumed silica to meet the standards of higher-grade applications, such as in food and pharmaceutical industries.
These results were independently verified by a global manufacturer of fumed silica, who had previously tested samples produced at the pilot plant. This validation confirms the quality and repeatability of the material and further cements the commercial potential of the FSR process.
According to PyroGenesis CEO P. Peter Pascali, the company initially focused on producing a baseline fumed silica product that met basic client specifications. With this goal achieved, the current and upcoming phases aim to fine-tune the system to produce a wider range of fumed silica grades, targeting both industrial and high-purity applications. Pascali emphasized that the ability to tailor grades is vital for penetrating different market segments, from rubber and paints to pharmaceuticals and food additives.
Another key differentiator of the PyroGenesis FSR technology is its clean production process. Unlike traditional fumed silica manufacturing methods that generate hydrochloric acid (HCl) as a byproduct requiring post-processing removal, the FSR process produces no HCl. This simplifies production, lowers operational costs, and enhances environmental sustainability.
Fumed silica is widely utilized across numerous industries. It serves as a thickening agent and anti-caking additive in products such as toothpaste, powdered foods, cosmetics, adhesives, paints, sealants, thermal insulation materials, and batteries. As such, market demand for high-quality, cost-effective, and environmentally friendly fumed silica is strong and growing.
This project falls within PyroGenesis’ Commodity Security & Optimization vertical—one of its three strategic pillars, alongside Energy Transition & Emission Reduction and Waste Remediation. The vertical focuses on leveraging advanced technologies to recover valuable minerals and materials from industrial processes, thereby supporting critical raw material availability and sustainable resource management.
