Frontieras to Open West Virginia Plant to Turn Coal Into Fuel, Fertilizer

Frontieras North America closed on a riverfront property on Jan 19 at the Ohio border in West Virginia, where the company plans to build its first zero-emission commercial plant to turn coal into fuel, fertilizers, and other carbon products.

Upon completion, the $850 million project will be the company’s first coal reformation flagship facility in the United States. The energy and environmental technology company first announced the project in 2022.

Located in Mason County, the facility will be built on a 183-acre property along a 1-mile stretch of the Ohio River, allowing for barge transport, rail access, and close access to Appalachian coal reserves.

With a skilled regional workforce, the company projects the plant to process 2.7 million tons of coal each year—about 0.5 percent of U.S. coal production.

The project is expected to create more than 2,000 construction jobs and over 200 full-time positions, according to Frontieras.

West Virginia Gov. Patrick Morrisey hailed the announcement as a win for the state, which was chosen over locations in Texas and Wyoming because of its regional coal supply and logistical advantages, Frontieras said.

“Frontieras is completely aligned with our 50-by-50 energy plan and our red tape-cutting strategy,” Morrisey said in a statement. “This project strengthens our coal communities by creating new demand for Appalachian coal communities by creating new demand for Appalachian coal.”

The facility will use the company’s patented solid carbon fractionation, a new process that deconstructs coal by extracting volatiles, moisture, and contaminants. The process produces hydrogen, methane, naphtha, diesel, aviation fuel, and a clean coal. The company claims the plan will produce no waste and no emissions.

Construction is expected to start this year, with the plan scheduled for commissioning in the first half of 2028, according to the company.

Frontieras, which was formed in 2021, plans to continue expanding in the state and the region, according to CEO and co-founder Matthew McKean.

“We’ve experienced nothing but clear alignment and constructive support from Governor Morrisey’s office,” McKean said in a statement.

The company expects the Mason County facility to positively impact the state’s GDP, or total monetary value, by 3 percent.

Future plans for Frontieras include building processing facilities in Wyoming and Texas. Frontieras also holds patents in Canada, Russia, South Africa, Australia, and other countries where it plans to expand, according to the company’s website.

In April, Frontieras announced its support of President Donald Trump’s executive order re-establishing coal as a necessity for solving rising energy demands.

The orders eliminated unnecessary regulations and removed the government’s investment barriers, expedited mining opportunities on federal lands, and designated coal as a critical mineral, according to the company.

West Virginia coal has provided the economic foundation for the state’s economy for more than 100 years. The industry generates more than 20,000 direct mining jobs and more than 70,000 indirect jobs. It also generates more than $6 billion each year in economic impact for the state, according to the West Virginia Coal Association.