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

hi to hydrogen

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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Profit for Houston-based oil companies declined in Q1, but only on paper

Money Matters

Profit for the two largest oil companies in the U.S. tumbled during the first quarter, a three-month period in which the price of crude and gasoline rocketed higher. It's a setback on paper only, however, the result of financial hedges that backfired after the U.S. and Israel launched attacks on Iran in late February.

Exxon Mobil and Chevron reported quarterly results on Friday, May 1, with adjusted profits for both companies topping Wall Street expectations. The shares of both companies, up sharply this week, ticked higher before the opening bell.

With energy prices depressed at the start of the year, Exxon Mobil and Chevron had arranged hedges to offset volatility, a standard practice in the industry. Companies and investors through hedges lock in a price in advance to protect themselves from futures swings. That can provide them with some predictability on costs.

In the aftermath of an attack by the U.S. and Israel on Iran, however, the physical delivery of oil became impossible with the Strait of Hormuz essentially closed. Exxon and Chevron cannot book gains on those hedges until the crude is physically delivered.

The near closure of the Strait of Hormuz off the coast of Iran is a flashpoint in the war and the source of much of the economic pain being felt globally. About 20% of the world’s oil passes through the strait on a typical day, but the passage has been choked off since the war began in late February.

Exxon earned $4.18 billion, or $1 per share, for the period ended March 31. A year earlier it earned $7.7 billion, or $1.76 per share. The company lost almost $4 billion in the quarter on what it called “unfavorable estimated timing effects” of its hedges.

Removing such one-time impacts, Exxon earned $1.16 per share, 9 cents better than Wall Street projections, according to a survey by Zacks Investment Research predicted. Exxon does not adjust its reported results based on one-time events such as asset sales.

Revenue totaled $85.14 billion, breezing past Wall Street's expectation of $81.49 billion.

First-quarter net production was 4.6 million oil-equivalent barrels per day. That’s down from 5 million oil-equivalent barrels per day in the previous quarter.

“If you look at the unprecedented disruption in the world’s supply of oil and natural gas, the market hasn’t seen the full impact of that yet," CEO Darren Woods said during a conference call. "So there’s more to come if the strait remains closed, why haven’t we seen those impacts manifest themselves fully in the market yet? Well, I think we all know there was a lot of water and a lot of oil in transit on the water, a lot of inventory on the water.”

Chevron reported a first-quarter profit of $2.21 billion, or $1.11 per share. It earned $3.5 billion, or $2 per share, a year earlier.

The company said that its quarter included a $360 million net loss related to a legal reserve and that foreign currency effects lowered earnings by $223 million.

Chevron's adjusted profit was $1.41 per share, easily beating the 92 cents per share Wall Street was calling for. Like Exxon, Chevron does not adjust its reported results based on one-time events such as asset sales.

The company's revenue totaled $48.61 billion, also better than expected.

Exxon and Chevron are among the big drillers reporting earnings this week. On Tuesday BP said that its first-quarter profit more than doubled.

The oil companies' results come at a time when gasoline prices in the U.S. hit new multiyear highs, a point of increasing agitation for travelers, households and also businesses that are particularly sensitive to higher energy prices.

The average price of gasoline in the U.S. hit $4.39 on Friday, according to motor club AAA, up more than 8% this week.

Inflation in the U.S. rose sharply in March, fueled by the largest jump in gas prices in six decades, according to data from the U.S. Department of Labor. The surge in gas prices has squeezed the budgets of lower- and middle-income families, making it more difficult to pay for necessities.

But it’s disrupting businesses as well, particularly those sensitive to higher fuel costs. Airlines worldwide have begun canceling flights as the war in the Middle East strains jet fuel supplies and pushes up ticket prices.

Oil prices eased on May 1, helping to steady the relatively few stock markets open worldwide on the May Day holiday.

6+ must-attend Houston energy transition events for May 2026

Mark Your Calendars

Editor's note: May is starting off strong with two of the month's largest events beginning on Monday, May 4: Enverus Evolve Conference and OTC. Mark your calendars and begin registering now.

May 4-6, 2026 — Enverus Evolve Conference

Staying ahead of the curve in the energy sector is critical. This conference is designed to equip energy leaders with foresight in the energy market, providing cutting-edge technological know-how, sessions and networking opportunities industry leaders, and offering practical guidance on how to apply technology to solve big problems.

This event begins May 4 at Marriott Marquis, Downtown Houston. Register here.

May 4-7, 2026 — OTC 2026

The world’s largest offshore energy technology event returns to Houston beginning May 4. Dr. Mohamed Irfaan Ali, president of the Co-operative Republic of Guyana, will officially open the 2026 Offshore Technology Conference, delivering the Opening Address on May 4. This year's event will be cover the theme of "Steering Offshore Energy Innovation into the Future," emphasizes the pivotal role oil and gas, along with other emerging offshore energy sources, will play in shaping a sustainable and energy-secure future.

This event begins May 4 NRG Park. Register here.

May 14, 2026 — Gulf Coast ASSP Energy Corridor Section Meeting

At this lunchtime session, Chris Garza will speak on “Demystifying Regulatory Frameworks.” This session provides a comprehensive overview of key regulatory requirements concerning air quality, water discharge, and land management. Attendees will gain actionable insights into permits, reporting obligations, pollution prevention planning, and hazardous waste management. This session demystifies regulatory frameworks and empowers businesses to meet their legal responsibilities while promoting a culture of environmental stewardship. Attendees are welcome to stay for lunch and networking after the session.

This event takes place May 14 at 960 Memorial City Way. Register here.

May 16, 2026 — Energy Valuation Conference

ASA Houston's 16th annual EVC brings together energy valuation professionals and industry thought leaders to present timely educational valuation topics, with a focus on valuation impacts in the transition of power generation from fossil fuel to non-carbon, renewables, sustainable energy

This event takes place May 16 at The Briar Club, and there will be a live webcast. Register here.

May 18-19, 2026 — Geothermal Transition Summit North America

This two-day summit serves as the meeting point for the geothermal and oil and gas industries and will focus on geothermal energy, including scaling plants and navigating state regulations. The event promises 40 expert speakers, 15 exhibition spaces, and networking opportunities with 250 industry decision makers.

This event begins May 18 at Norris Conference Center. Register here.

May 20-21, 2026 — ESF North America

ESF North America returns for its 5th edition, under the theme of “innovation and adaptation.” Attendees will explore how technology, innovation, and collaboration can drive a resilient, competitive refining and chemicals industry.

This event begins May 20 at The Westin Oaks Houston at the Galleria. Register here.

Houston scientists unveil faster, low-energy method to recycle lithium-ion batteries

Battery breakthrough

Rice University researchers have uncovered a more energy-efficient and faster way to recycle critical minerals from used lithium-ion batteries.

Traditional methods rely on high heat, long processing times and harsh chemicals to recover a small fraction of critical materials from batteries used in everything from smartphones to electric vehicles. However, the team from Rice's Department of Materials Science and Nanoengineering developed a process that uses a water-based solution containing amino chlorides to extract more metals in less time

The team published the findings in a recent edition of the scientific journal Small.

Simon King, a sophomore studying chemical and biomolecular engineering who completed this work as a summer research fellow at the Rice Advanced Materials Institute, served as first author of the study. He worked with corresponding authors Pulickel Ajayan, the Benjamin M. and Mary Greenwood Anderson Professor of Engineering, and Sohini Bhattacharyya, a research scientist in Ajayan’s lab.

By using a hydroxylammonium chloride (HACI) solution, the team achieved roughly 65 percent extraction of key battery metals in just one minute at room temperature, according to the study. The efficiencies grew to roughly 75 percent for several metals under longer processing times.

“We were surprised by just how fast the reaction occurs, especially without the involvement of high temperatures,” King said in a news release. “Within the first minute, we’re already seeing the majority of the metal extraction take place.”

By not requiring high temperatures or long reaction times, Rice predicts the process could have a major impact on cost and the environmental impact of lithium battery recycling. Additionally, the water-based HACI solution makes waste handling easier and lowers certain environmental risks.

In addition to extracting the materials, the team went on to demonstrate that the recovered metals could be recycled and reprocessed into new battery materials.

“A big advantage of this system is that it works under relatively mild conditions,” Ajayan added in the release. “That opens the door to more sustainable and scalable recycling technologies.”

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