Impact Minerals Validates US-Based Commercial-Scale HPA Facility with Positive Scoping Study

Impact Minerals (ASX: IPT) has announced positive results from a scoping study for the development of a commercial-scale high purity alumina (HPA) facility in the US, using patented technology developed by its 50% share in associated company Alluminous.

Completed by NewPro Consulting & Engineering Services, the early-stage study assessed four development cases in Western Australia and Texas to support a technically credible pathway to commercialisation and justify proceeding to the next phase of engineering and process de-risking.

While all cases generated positive post-tax financial returns, Alluminous identified a US Gulf Coast facility as its preferred commercial development pathway due to its lower-cost and more strategic location.

The study is a preliminary (FEL-0) estimate with a wide accuracy range of +50% to −30%, meaning further pilot testing, product qualification, sales contracts, funding, site selection, and permitting are required before any final investment decision is made.

Staged Production Increase

The US option offers a staged increase in production from 2,000 tonnes per annum to 4,000tpa as product quality, offtake sales contracts, and funding support the step-up, providing a post-tax net present value of $518 million and 42.3% internal rate of return with a capital payback of 3.8 years.

For the same 2,000tpa plant, the US case would require approximately 26% less upfront capital and would have 18% lower operating costs than a Perth location, while also fitting the US drive to build local critical materials supply.

At the full 4,000tpa, the facility is modelled at US$74m of total installed capital (or about US$18.5m per 1,000tpa), and as the process uses a widely available and locally sourced chemical feedstock, similar plants could be built in multiple locations near other customers.

The financial outcome supports Alluminous’ business model for establishing its first full-scale commercial facility in the US and it has received support its two US-based institutional investors.

Ground-Breaking Approach

Impact managing director Dr Mike Jones said Alluminous technology represented a ground-breaking approach to HPA production.

“HPA is a high-tech minerals market and these projects face a persistent chicken-and-egg problem—lenders generally require a binding offtake agreement before financing scale-up, while potential customers want confidence in a reliable supply before committing to long-term volumes,” he said.

“The preferred case in this study offers a practical pathway through that problem, showing industry-leading capital efficiency per tonne of HPA produced and competitive operating costs, both of which have room for improvement.

“The cost advantage of a US facility, together with an accelerating US push to onshore critical minerals and advanced materials supply chains, supports locating Alluminous’ first full-scale commercial plant in the US.”

Dr Jones said Australia remained central to the Alluminous strategy and the company planned to expand its Perth HPA pilot plant into a demonstration and technology development hub with a capacity of up to 200tpa, subject to design, funding and approvals.

Alluminous Investment

Impact became the largest shareholder in Alluminous in April 2025, when it purchased a 50% interest in the company for $1.1m as part of the acquisition of HiPurA HPA processing technology from the administrators of previous owner ChemX Materials.

The acquisition offered the opportunity to accelerate Impact’s entry into the HPA market by as much as to two years, providing a significant time and cost advantage compared to earlier forecasts.

The remaining 50% of Alluminous is owned by the two founders and inventors of HiPurA technology, together with North American venture capital investors with experience in the resource sector.

The ownership structure may facilitate access to North American capital markets and provide Impact with exposure to additional funding opportunities and global customer networks in high-growth HPA sectors including batteries, semiconductors, and LEDs.