AUS
NZ
UK
CA
USA
IND
Highlights
PyroGenesis’ fumed silica reactor achieved a surface area of 136 m²/g, a threefold increase from the previous test and within commercial grade ranges.
August testing confirmed elimination of carbon impurities, improved purity levels, and increased SiO₂ content to 97.92%.
Reactor yield doubled, producing 10 batches in half the time of the prior test, confirming progress toward commercial readiness.
PyroGenesis Inc. (TSX:PYR) (FRA:8PY1) announced significant advancements from performance trials of its fumed silica reactor (FSR) pilot plant, conducted in August 2025. The company, which designs and commercializes plasma-based sustainable solutions for heavy industry, reported that the latest operational tests have resulted in critical improvements to multiple product parameters, moving the system closer to commercial deployment.
The results were independently validated by a global manufacturer of fumed silica, who analyzed samples submitted by PyroGenesis.
Key Test Outcomes
Surface area measurements—a primary indicator of product performance and market value—reached 136 m²/g in the latest test series, compared to 44 m²/g in the previous trial and 26 m²/g in earlier stages. This places PyroGenesis’ fumed silica within the commercial ranges for grades 90 (75–105 m²/g) and 130 (105–155 m²/g), and at the lower end of grade 150 (135–165 m²/g). The company’s long-term target remains 300 m²/g.
Carbon impurities were fully eliminated, with measurements reduced to 0% from 0.32% in the last test and 2.32% in test 4. Purity also advanced, with reductions in TiO₂ to 0.0025%, Al₂O₃ to 0.0422%, and Fe₂O₃ to 0.0339%. SiO₂ levels rose to 97.92%, compared with 53.59% in earlier testing.
In addition, loss on drying improved to 0.6%, surpassing commercial requirements of ≤1% for grades 90 and ≤1.5% for grades 130–300.
Reactor productivity also increased: test 6 produced 10 batches in half the time it previously took to generate five batches in test 5. pH testing confirmed the chemical-free nature of the process, with results at 8.3, compared to conventional methods that produce acidic byproducts with pH levels below 7.
Market Context and Industry Applications
Fumed silica is a widely used industrial input, present in thousands of products ranging from cosmetics, pharmaceuticals, adhesives, and food products to advanced applications in tires, batteries, and fiber optics. Its performance value is closely tied to surface area measurements, which affect consistency, flow, and stability of end-use materials.
PyroGenesis developed the FSR pilot plant for HPQ Polvere Inc., a subsidiary of HPQ Silicon Inc. PyroGenesis holds a 50% interest in Polvere and has an exclusive arrangement to supply equipment for commercialization of the technology.
The company’s plasma-driven approach to fumed silica production aligns with its broader Commodity Security & Optimization vertical, which aims to maximize resource efficiency, improve critical mineral supply, and provide sustainable industrial solutions. PyroGenesis’ other solution verticals include Energy Transition and Emission Reduction, and Waste Remediation.
About PyroGenesis
PyroGenesis Inc., headquartered in Canada, specializes in advanced plasma technologies designed to reduce greenhouse gas emissions and provide sustainable alternatives to traditional industrial processes.
