Independent Analysis Confirms HPQ Fumed Silica Reactor Produces Commercial-Grade Material at Pilot Scale
Executive Summary
- Independent laboratory analysis of material from Test #7 confirms commercial‑grade fumed silica with surface area up to 191 m²/g and purity of 99.8 %, meeting the upper end of industry specifications.
- The results demonstrate a 20–40 % improvement in specific surface area and a jump from ~98 % to >99 % purity versus Test #6, validating scalability of HPQ’s proprietary plasma‑based FSR technology.
- HPQ plans to scale the pilot facility to its full design capacity of 50 tonnes per year and begin sampling for potential industrial partners, moving the project into the commercialization stage.
Key Details
- Test #7 Laboratory Results (Covalent Metrology):
- Specific Surface Area (BET): 168.44 – 191.17 m²/g (up from 136 m²/g in Test #6).
- Product Purity (ICP‑MS): 99.74 % – 99.83 % (up from 97.92 % in Test #6; above the 99 % commercial baseline).
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XRD Analysis: Fully amorphous powder, confirming true fumed silica structure.
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Comparative Performance:
- Surface‑area improvement of 20–40 % over previous pilot test.
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Purity increase of ~2 percentage points, surpassing the 99 % commercial threshold.
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Technology Highlights:
- Single‑step plasma process converts quartz (SiO₂) directly to hydrophilic fumed silica—no chlorosilanes, no HCl by‑products.
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Energy consumption reduced by up to 87 % versus conventional routes; CO₂‑equivalent emissions cut by 84 %.
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Pilot Facility:
- 20× larger than the original lab setup; designed for continuous operation at 50 t/yr capacity.
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Seven test campaigns conducted in 2025 to optimize feedstock, energy profile, and reactor stability.
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Next Steps:
- Optimize production to maintain ~200 m²/g surface area consistently.
- Ramp pilot plant toward full‑design throughput of 50 t/yr.
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Distribute sample batches under NDAs to potential partners in coatings, polymers, and advanced materials sectors.
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Commercial Outlook:
- Global fumed‑silica market projected > US$2.57 bn by 2034; HPQ’s cost and sustainability advantages position it for meaningful market share.
Notable Quotes
“Replicating and surpassing lab‑scale results at a commercial pilot scale is a defining moment for HPQ… the FSR technology can now consistently deliver industrial‑grade material sustainably.” – Bernard Tourillon, President & CEO, HPQ Silicon Inc.
“Our process eliminates the costly environmental footprint of traditional fumed‑silica manufacturing… we are proving that sustainability and profitability can coexist.” – Bernard Tourillon