Element Fuels Completes Site Prep for Hydrogen Refinery & Power Plant

Element Fuels Holdings, LLC, a company dedicated to advancing scalable, next-generation clean fuels production, has completed site preparation and pre-construction for a cutting-edge hydrogen-powered refinery and combined-cycle power plant at the Port of Brownsville, Texas. The Element complex employs innovative technologies to produce and recycle hydrogen, aiming to generate cleaner, higher-quality fuels, including high-octane gasoline and electricity for commercial and consumer use.

Founder and Co-CEO John Calce announced, “Element Fuels has secured permits to construct and operate a refinery capable of producing over 160,000 barrels, or approximately 6.7 million gallons, per day of finished gasoline, diesel, and jet fuel. This permit marks a significant milestone, with no refinery of this scale and functionality permitted in the United States since the 1970s.”

Scheduled for operation in 2027, Element Fuels’ groundbreaking refinery integrates advanced, proven technologies to process high gravity domestic shale oil, yielding low-carbon intensity fuels that substantially reduce carbon emissions. The facility will also generate low-carbon hydrogen to fulfill its fuel requirements, effectively eliminating CO2 emissions. Excess hydrogen will power Element’s hydrogen-capable combined-cycle gas turbine power plant, contributing over 100 MW of electricity to support the Energy Reliability Council of Texas (ERCOT).

Calce emphasized, “Element Fuels is pioneering the next generation of clean fuels while demonstrating the feasibility of producing higher-quality, cleaner, higher-octane fuels that advance the energy transition.”

Spanning more than 240 acres, the Element complex at the Port of Brownsville aims to boost the local economy by creating hundreds of jobs with above-market wages. Additionally, Element Fuels is collaborating with local and Port authorities to support the Justice40 initiative, promoting a climate-positive environment and providing clean energy and sustainable housing for the Brownsville area and Rio Grande Valley residents.

McDermott, engaged to provide front-end engineering design services for the facility, including offsites and utilities, expressed confidence in their partnership with Element Fuels. Rob Shaul, Senior Vice President, Low Carbon Solutions at McDermott, stated, “We are dedicated to advancing low carbon pathway projects and are poised to support Element Fuels throughout this unique project’s next phases.”

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