hi to hydrogen

Houston clean fuels producer reaches milestone on South Texas hydrogen-powered refinery

Element Fuels has designed the plant to produce and recycle hydrogen that will generate and deliver cleaner, higher-quality fuels. Photo via Getty Images

Houston-based Element Fuels has completed the pre-construction phase of its hydrogen-powered clean fuels refinery and combined-cycle power plant in the Port of Brownsville.

Element Fuels, which has contracted with Houston-based McDermott to provide front-end engineering design services for the project, has designed the plant to produce and recycle hydrogen that will generate and deliver cleaner, higher-quality fuels, including much-needed high-octane gasoline and electricity for commercial and consumer consumption.

“Element Fuels has received the necessary permitting to construct and operate a refinery capable of producing in excess of 160,000 barrels, or approximately 6.7 million gallons, per day of finished gasoline, diesel, and jet fuel,” Founder and Co-CEO of Element Fuels John Calce says in a news release. “A permit for a greenfield refinery of this size, scope, and functionality has not been granted in the United States since the 1970s. This speaks to the innovative approaches we are taking to address climate and sustainability concerns in cleaner, greener ways that are new to the refinery space.”

The project is expected to go online in 2027 and will produce enough low-carbon hydrogen to supply approximately 100 percent of the refinery’s fuel requirements, essentially eliminating CO2 emissions, per the news release. More than 100 megawatts of excess electricity generated from the power plant will be provided to the Energy Reliability Council of Texas for the surrounding community’s needs.

“Element Fuels is not only ushering in the next generation of clean fuels, we’re also proving that, without a doubt, there is a way to produce higher quality, cleaner, higher-octane fuels that significantly advance the energy transition," Calce continues. "This changes everything – for the industry, for consumers, and for the well-being of the planet.”

The plant is located in South Texas and built on more than 240 acres within the Port of Brownsville. Element Fuels is reportedly collaborating with local and Port officials "to advance the Justice40 initiative established by the U.S. Department of Commerce to contribute to a climate-positive environment that provides residents of the Brownsville area and Rio Grande Valley with clean energy and affordable and sustainable housing," per the release.

“Building on our successful collaboration during early project phases, we believe we are uniquely positioned to leverage our expertise and knowledge to further support Element Fuels throughout the next stages of this unique project,” adds Rob Shaul, senior vice president at Low Carbon Solutions at McDermott. “We remain focused on the delivery of low carbon pathway projects and are committed to advancing the landscape of energy production.”

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A View From HETI

A new joint venture will work on four projects supplying 5 gigawatts of power from combined-cycle power plants for the ERCOT and PJM Interconnection grids. Photo via Getty Images.

Houston-based power provider NRG Energy Inc. has formed a joint venture with two other companies to meet escalating demand for electricity to fuel the rise of data centers and the evolution of generative AI.

NRG’s partners in the joint venture are GE Vernova, a provider of renewable energy equipment and services, and TIC – The Industrial Co., a subsidiary of construction and engineering company Kiewit.

“The growing demand for electricity in part due to GenAI and the buildup of data centers means we need to form new, innovative partnerships to quickly increase America’s dispatchable generation,” Robert Gaudette, head of NRG Business and Wholesale Operations, said in a news release. “Working together, these three industry leaders are committed to executing with speed and excellence to meet our customers’ generation needs.”

Initially, the joint venture will work on four projects supplying 5 gigawatts of power from combined-cycle power plants, which uses a combination of natural gas and steam turbines that produce additional electricity from natural gas waste. Electricity from these projects will be produced for power grids operated by the Electric Reliability Council of Texas (ERCOT) and PJM Interconnection. The projects are scheduled to come online from 2029 through 2032.

The joint venture says the model it’s developing for these four projects is “replicable and scalable,” with the potential for expansion across the U.S.

The company is also developing a new 721-megawatt natural gas combined-cycle unit at its Cedar Bayou plant in Baytown, Texas. Read more here.

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