Alpha HPA (ASX: A4N) is pioneering a cleaner, smarter way to produce high purity alumina (HPA) – one of the critical materials enabling the global transition to clean energy and advanced technologies. From semiconductors and lithium-ion batteries to Direct Lithium Extraction (DLE), synthetic sapphire and LED lighting, HPA plays a vital role in powering future-facing electronics, energy storage and sustainable mobility.
Yet for decades, producing HPA came at a cost – expensive feedstocks, energy-intensive processes and a heavy carbon footprint. With our Smart SX Technology, we have created a new way to purify aluminium into ultra-high purity materials that is more efficient, scalable and dramatically lower in emissions.
FROM EARLY APPLICATIONS TO BREAKTHROUGH TECHNOLOGY
In the 2010s, electric vehicles were just starting to take off. Tesla had just released its Model S, and one of the first major applications for high-purity alumina (HPA) was in battery separators. We saw this emerging use and asked: how could we make HPA production better?
Our search led us to a solvent extraction (SX) processing technology. While solvent extraction itself is not new, it had never been successfully applied to aluminium until now. This technology enabled Alpha HPA to produce HPA more efficiently and, in doing so, created an extraordinary technological advantage.
By early 2018, Alpha HPA was piloting this breakthrough process, setting the foundation for a new era of high-purity aluminium materials and positioning the company at the forefront of innovation in this rapidly growing market.
ADAPTING SOLVENT EXTRACTION FOR ALUMINIUM
At the heart of our innovation story is SX, a well-established method used worldwide to refine metals like nickel, cobalt and uranium. Our Smart SX technology is the first adaptation of this technique to aluminium – delivering a cleaner, more flexible and scalable pathway to high-purity products.
Smart SX offers three major advantages:
- Lower carbon – up to 70% less CO₂ as we do not use finished aluminium as our feedstock like in traditional HPA processes
- Resource-efficient – 100% reagent recycling, near-zero waste and powered by renewable electricity
- Scalable and flexible – capable of producing the full suite of aluminium oxides, hydroxides and nitrates, tailored for industries from energy to electronics
This makes Smart SX not just an incremental improvement, but a disruptive technology with the potential to reset the industry’s benchmarks for cost, purity and sustainability.
SCALING FROM BEAKERS TO MARKETS
Steps to commercialisation
Bringing Smart SX Technology from the lab to large-scale production has been a multi-stage process:
- Benchtop trials
The chemistry and principles of Smart SX were proven and refined at laboratory scale over a three-year period. - Pilot operation
A continuous pilot rig was established in Rocklea and then later moved to Murarrie between 2019 and 2021 to replicate industrial conditions, focusing on process stability and optimisation. These pilot campaigns demonstrated that Smart SX worked as a concept. - Demonstration Facility 1 (50 kg/day)
The first scaled-up SX circuit validated our ability to run the full process end-to-end and demonstrated that Smart SX could be scaled beyond the lab, setting the foundation for commercial deployment. - Demonstration Facility 2 (80 kg/day)
Customer demand drove further scale-up. Larger product volumes were produced and supplied to industry partners, providing qualification samples and valuable process data. This site now operates as our Product Development Centre in Morningside, Brisbane, where products are bespoke engineered for specific customer needs. - HPA First Project – Stage One (1 t/day, ~350 tpa)
As customer demand grew, we needed to secure the funding required to prove commercial scale. Stage One of the HPA First Project was constructed in Gladstone between 2021 and 2022, marking the first small-scale commercial operation of Smart SX Technology. Maiden product was produced in November 2022, proving the process could be scaled to attract investment and enable product qualification with customers. The facility now operates continuously, powered by renewable electricity, and produces a broad portfolio of high-purity aluminium products, including:- ULTRA AAP™ – Ultra-High Purity Alpha Phase Alumina (Al₂O₃) Powder
- ULTRA GAP™ – Ultra-High Purity Gamma Phase Alumina (Al₂O₃) Powder
- ULTRA GAP-X™ – Ultra-High Purity Gamma/Eta Phase Alumina (Al₂O₃) Powder
- ULTRA TAB™ – Ultra-High Purity Alumina (Al₂O₃) Tablets
- ULTRA NAP™ – Ultra-High Purity Nano Alumina (Al₂O₃) Powder
- ULTRA HPB™ – Ultra-High Purity Pseudoboehmite (Al-O-OH) Powder
- ULTRA ALN™ – Ultra-High Purity Aluminium Nitrate (Al(NO₃)₃·9H₂O)
- ALN_ACS™ – Aluminium Nitrate Nonahydrate (Al(NO₃)₃·9H₂O), ACS Grade
- ULTRA ATH™ – Ultra-High Purity Alumina Tri-Hydrate (Al(OH)₃)
- ULTRA SAPPHIRE™ – Synthetic Sapphire (Al₂O₃)
This portfolio demonstrates the breadth, flexibility and scalability of the Smart SX process. Beyond these products, Alpha HPA also works with customers to develop bespoke high-purity aluminium materials tailored to specific technical requirements.
- HPA First Project – Stage Two (120 t/day, ~10,000 tpa)
Stage Two is under construction in Gladstone due to be commissioned in 2027, and will be the world’s largest single-site manufacturing facility for high-purity aluminium materials, spanning 10 hectares. The project reached Final Investment Decision in May 2024 and construction commenced mid-2024. With advanced automation and process control, it will scale Smart SX to full industrial capacity and position Alpha HPA as a global leader in sustainable HPA production.
WHY SMART SX MATTERS
The impact of Smart SX at Alpha HPA extends far beyond the initial application of EV batteries. By producing ultra-high purity aluminium materials at lower cost and carbon intensity, the technology is enabling industries worldwide to decarbonise and innovate.
- Semiconductors – improving performance and reliability in the chips that power everything from smartphones to electric vehicles
- Lithium-ion batteries – enhancing safety and efficiency in energy storage for transport and grid applications
- Direct Lithium Extraction (DLE) – supporting next-generation, lower-impact lithium recovery methods
- Synthetic sapphire – providing the foundation for advanced optics, aerospace and durable consumer electronics
- LED lighting – delivering higher efficiency and lower energy consumption
Each of these markets is critical to the world’s transition to clean energy and advanced manufacturing. Smart SX Technology places Australia at the forefront of supplying these future-facing industries.
LOOKING AHEAD
From spotting early EV battery applications to pioneering a breakthrough in HPA production, our story with Smart SX Technology has been one of persistence, innovation and vision.
As Stage Two construction advances, we are set to meet rising global demand for high-purity aluminium products, while setting new benchmarks for sustainability in the sector.
For us, this has never been just about building a process – it’s about proving that cleaner, smarter pathways for critical materials are possible, and showing how Australian innovation can lead the way to a more sustainable future.
