PyroGenesis Advances Fumed Silica Technology Toward Commercial Scale

PyroGenesis Inc. has provided an update on its fumed silica business, highlighting progress in commercializing its plasma-based Fumed Silica Reactor (FSR). The technology converts quartz into fumed silica through a single-step process designed to simplify conventional production methods while reducing environmental impacts.

Traditional fumed silica manufacturing generally involves multiple processing stages and the use of chemicals that can generate hazardous by-products. PyroGenesis’ all-electric plasma-based FSR is designed to eliminate these harmful chemicals and associated hazardous waste. The company says the process can also reduce energy consumption and carbon emissions while supporting economically viable production at smaller plant sizes.

PyroGenesis developed the FSR for HPQ Silica Polvere Inc., a subsidiary of HPQ Silicon Inc. Following successful laboratory testing, the company constructed and commissioned a pilot plant in 2025. Within 12 months of operation, the facility demonstrated the ability to produce multiple commercial-grade fumed silica products, including grades 200 and 150. Grade 200 is widely used as a general-purpose material because of its balance of thickening, flow and versatility.

The technology has attracted interest from several industry participants. A major global fumed silica manufacturer previously signed a letter of intent covering the pilot-scale development program. After successful testing and third-party verification, discussions have progressed toward potential commercial deployment of the FSR.

PyroGenesis is also negotiating with a potential joint venture partner regarding a 1,000-tonne-per-year production facility. Under the proposed arrangement, PyroGenesis would exclusively manufacture the FSR for approximately US$20 million. However, negotiations have stalled over intellectual property, exclusivity and cost-related terms. PyroGenesis has submitted a compromise proposal that remains under review.

Meanwhile, a third potential customer has started discussions regarding large-scale fumed silica supply and possible production facilities in North America. Initial demand indications could support several FSR systems with capacities of tens of thousands of tonnes per year.

A fourth existing customer with significant Middle Eastern operations has also resumed discussions about establishing a local production facility. Negotiations planned for the second half of 2026 are currently focused on a potential 10,000-tonne-per-year plant.

PyroGenesis would retain exclusive manufacturing arrangements for plants associated with all four initiatives. The company believes its technology could support more localized production, reduce capital requirements and encourage greater supply-chain flexibility.

Fumed silica serves thousands of industrial and consumer applications, including coatings, adhesives, sealants, paints, inks, pharmaceuticals, agriculture, construction materials, cosmetics and batteries. Global market demand is expected to continue increasing, particularly across coatings, automotive, sealants and lithium-ion batteries.

PyroGenesis also holds rights under its agreement with HPQ to convert future fumed silica royalty rights into a 50% interest in Polvere. The company expects this process to be completed in the third quarter of 2026. It also retains an exclusive arrangement to supply equipment for future commercialization of the FSR.

Product Impact and Chemical Commodity Price Impact

The development strengthens the commercial outlook for fumed silica by demonstrating that PyroGenesis can produce multiple commercial grades through a lower-emission, single-step process. If customer agreements and new plants advance, the technology could support decentralized production and increase regional supply availability. In the near term, the news is unlikely to materially change global fumed silica prices because commercial capacity remains limited and negotiations are still underway. However, successful deployment of 10,000-tonne-per-year plants and larger systems could gradually increase supply and create downward pressure on regional fumed silica prices. Related commodities such as silicon dioxide and quartz could see stronger demand, while lower production costs may improve downstream margins in coatings, adhesives, sealants and battery applications.