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

Silambam Houston will use the funding to create the Green Mountain Energy Sun Club Sustainability Pavilion. Photo courtesy of Green Mountain

Green Mountain Energy Sun Club has supplied a grant of nearly $103,000 to a local Indian arts center to make sustainable improvements to its facilities.

Silambam Houston will use the grant to help with the installation of a rooftop solar array and a new pavilion at its Pearland dance studio, which will be called The Green Mountain Energy Sun Club Sustainability Pavilion. The venue will serve as an outdoor gathering space for events at the facility.

“At Green Mountain Energy, we recognize that our choices can have a profound impact on our environment,” Mark Parsons, Green Mountain Energy vice president, says in a news release. “We’re proud to support the rich and diverse culture of the Indian community, and we’re glad to help Silambam take the next step toward a more sustainable future.”

The 14.58 kW solar structure is expected to offset 100 percent of the building’s energy needs, which would save the organization more than $4,000 per year for the next 25 years. Sun Club has donated more than $14 million for 164 projects across Texas and the Northeast since it was founded in 2022.

Silambam is an Indian classical arts organization with an arts academy program that serves 180 students each week with more than 20 teaching artists on staff. The professional dance company has more than 20 dancers that regularly perform at Houston venues like Miller Outdoor Theater where they will perform next on June 7.

“We are thrilled to be able to weave sustainable practices into our arts programming, while also giving back to the community,” founder and executive artistic director of Silambam Dr. Lavanya Rajagopalan said in a news release. “The annual savings from this project will allow us to increase artist pay, provide tuition waivers for economically disadvantaged students, and/or provide free or pay-what-you-can access to our ArtStream Concerts, all while benefiting the environment.”

Silambam Houston will use the grant to help with the installation of a rooftop solar array and a new pavilion at its Pearland dance studio. Photo courtesy of Green Mountain

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