PyroGenesis Inc. (TSX: PYR, OTCQX: PYRGF, FRA: 8PY1) has reached a critical step forward in its development of an all-electric plasma process for producing fumed silica, a material that sits at the heart of countless products, from cosmetics and toothpaste to batteries and construction materials. Recent independent analysis confirms that the powder collected during pilot-scale testing is indeed high-quality fumed silica, with yields that have surpassed expectations and impurities at levels that are not only anticipated but easily managed.
The journey to this point began with rigorous lab-scale tests, which proved the viability of the technology. Now, at the pilot plant scale, PyroGenesis is validating its ability to scale up production while maintaining the quality of the fumed silica produced. The company recently announced it had successfully collected powder from the product recovery unit, or “baghouse,” and sent samples to an independent laboratory for analysis.
The results are clear, the powder is fumed silica, any impurities detected are within expected and manageable ranges, and the quantity produced exceeded forecasts, all positive indicators for the project’s future economics. In a side-by-side comparison, PyroGenesis’ material closely resembles the microstructure and complexity of commercial-grade fumed silica produced by industry leader Evonik Corporation, typically ranging in surface area from 150 to 200 m²/g.
With this validation in hand, the focus now shifts to two main objectives. First, the team will work on enhancing product purity by refining powder morphology and viscosity. Second, they aim to meet the production target of 50 tonnes per year. In parallel, the pilot plant will undergo a series of optimization tests designed to improve process control, increase silica conversion efficiency and yield, and boost product surface areas.
These optimization efforts are essential for scaling up the technology and making it commercially viable. The data gathered will inform the necessary equipment modifications and process adjustments, ultimately determining how well the product fits into the broader market.
Fumed silica is one of the most versatile industrial materials in use today. It can be found in everything from personal care products and cosmetics to paints, adhesives, and even thermal insulation. Its primary role is as a thickening or anti-caking agent, helping to stabilize and improve the texture and consistency of a wide range of end products.
PyroGenesis’ work in this area is part of its broader strategy to address key economic drivers in global heavy industry. The development of fumed silica from quartz falls under the company’s Commodity Security and Optimization vertical, which focuses on advanced material production techniques and the use of technology-like plasma to recover valuable metals, chemicals, and minerals from industrial waste. This approach not only maximizes raw materials but also improves the availability of critical minerals, supporting industries as they transition to more sustainable practices.
“Today’s announcement is a significant milestone that increases the probability of success for this project,” said P. Peter Pascali, President and CEO of PyroGenesis. “While we still have important steps to prove out, we are very pleased with the results of this analysis, as it confirms our theoretical expectations at a key stage in the overall project.”
PyroGenesis remains committed to advancing its all-electric plasma processes and sustainable solutions, which offer economically attractive alternatives to conventional, more polluting methods. The company’s expertise in plasma technology is being recognized by major industry players in markets such as iron ore pelletization, aluminum, waste management, and additive manufacturing. With a strong team of engineers, scientists, and technicians based in Montreal, and manufacturing facilities spanning over 6,700 m², PyroGenesis is well positioned to continue driving innovation in sustainable industrial solutions.
The successful pilot-scale production and independent verification of fumed silica mark a significant step forward for PyroGenesis. As the company refines its processes and works toward commercial-scale production, it is poised to make a meaningful impact on industries that rely on this critical material.
