HPQ Silicon Inc., a technology company focused on green engineering processes, announced a significant advancement in the pilot-scale testing of its proprietary Fumed Silica Reactor (FSR) process, developed by HPQ Silica Polvere Inc. (HSPI).

HSPI’s technology provider, PyroGenesis Inc., reported the successful completion of a detailed examination and analysis of material produced during the initial batch test at the Fumed Silica Reactor (FSR) pilot plant on Feb. 27, 2025. The findings confirm that the morphological characteristics and overall appearance of the produced material closely match those previously observed during initial lab-scale testing.

This validation marks a critical milestone, enabling HSPI to confidently move forward with planning and implementing necessary process improvements at the pilot plant. These enhancements are aimed at achieving the consistent production of commercial-grade fumed silica.

“During our lab-scale testing, we implemented crucial process improvements that enabled us to achieve commercial-quality material,” said Bernard Tourillon, President & CEO of HPQ Silicon and HPQ Silica, in a statement. “With the pilot plant now producing material with visual morphological characteristics aligning with our earlier lab-scale results, we’re more confident than ever in our ability to replicate—and even accelerate—this success. Having clearly identified how to refine our approach, we’re positioned to quickly advance toward commercial-grade production with the FSR.”

The achievement directly supports the progression of the FSR technology by establishing a solid technical foundation for the next phase of its development. The detailed analysis conducted will inform the specific process enhancements required to ensure the consistent production of commercial-grade fumed silica. Furthermore, this validation is an integral part of HSPI’s systematic approach to scaling its proprietary technology, transitioning from laboratory experimentation to pilot-scale implementation.

P. Peter Pascali, President and CEO of PyroGenesis Inc., emphasized the innovative nature of the technology. “Since 1944, the fumed silica industry has relied on conventional, fossil-fuel-intensive production methods. PyroGenesis is committed to breaking that cycle through innovation,” Pascali said. “Our Fumed Silica Reactor technology represents a revolutionary shift—scaling up a plasma-based process that eliminates carbon emissions while maintaining superior product quality. By decarbonizing this industry, we are enhancing efficiency, thereby setting a new standard for sustainable, commercially viable fumed silica production. This empowers HSPI’s clients with a cleaner and more reliable process.”

The successful morphological validation represents a key step forward for HPQ Silicon and HSPI in their efforts to commercialize a potentially disruptive and environmentally friendly method for producing fumed silica, a widely used material in various industrial applications. The focus now shifts to implementing the identified process improvements to achieve the desired commercial quality and prepare for larger-scale production.