FASForm™: Next GenerationFuel-Discovery Technology

Frontieras’ patented FASForm™ process uses Solid Carbon Fractionation to unlock abundant fuels, chemicals, fertilizer, and more from coal. One feedstock turns into six product streams.

See how FASForm™ works

A closer look

See the
process in motion.

How FASForm™ technology turns the world’s most abundant energy resource into fuels, fertilizer and industrial products.

Company video published October 6, 2026 · 4:46Watch on YouTube

Frontieras: The Next Standard in Energy Technology

Solid Carbon Fractionation

We turn coal into fuel.

FASForm™ uses heat (not burning) to separate coal into solid carbon, liquids and gases, then refines each stream into a market product.

9 countries
FASForm™ patents granted on five continents, including the U.S. and Canada
91%
of global coal production is in countries where FASForm™ is patented
3.8 billion
people live in those nine countries
33%
of the world’s electricity still comes from coal
7,500 tons
of coal a day, the design capacity of each planned facility
2.3 barrels
of liquid fuels from each ton of coal, by design

Sources: national patent grants; World Bank population, 2024; Ember, Global Electricity Review 2026; company design figures.

Hear our CEO and CTO speak about FASForm™.

Frontieras’ CEO and CTO explain how Solid Carbon Fractionation works.

Company video published October 1, 2021 · 3:19Watch on YouTube

Our Technology: Solid Carbon Fractionation

Six revenue streams

One feedstock.
Six revenue streams.

Six products for energy, industry and agriculture, all from a single feedstock.

01 / Revenue stream

Naphtha

Petrochemicals

A light liquid intermediate for petrochemical feedstock and blending markets.

Discuss the technology
Clear naphtha in laboratory glassware
Illustrative image, not an actual product sample.

02 / Revenue stream

Jet fuel

Aviation

A jet fuel–grade kerosene fraction for aviation markets.

Discuss the technology
Pale kerosene in a laboratory beaker
Illustrative image, not an actual product sample.

03 / Revenue stream

Diesel

Transportation

A diesel-range liquid for transportation.

Discuss the technology
Liquid product in a glass bottle at the Texas demonstration unit
Actual sample from the Texas demonstration unit.

04 / Revenue stream

FASCarbon™

Power generation

An upgraded solid-carbon product for thermal and industrial uses, with moisture and selected contaminants removed.

Discuss the technology
FASCarbon™ produced by the FASForm™ process
Actual sample from the Texas demonstration unit.

05 / Revenue stream

Sulfuric Acid

Industrial chemistry

Sulfur captured from the feedstock is converted into sulfuric acid for industrial chemistry.

Discuss the technology
Sulfuric acid in a glass reagent bottle
Illustrative image, not an actual product sample.

06 / Revenue stream

Ammonium Sulfate

Agriculture

Nitrogen captured from the feedstock is converted into ammonium sulfate fertilizer for agriculture.

Discuss the technology
Ammonium sulfate granules
Illustrative image, not an actual product sample.

Hydrogen is produced and consumed on site as part of the process-fuel mix; it is not sold as a product.

  1. 01 Feedstock

    Coal

    Coal and other solid hydrocarbons enter the process.

  2. 02 Fractionate

    Oxygen-deficient conditions

    Controlled heat

    Thermal separation and cracking, without burning the feedstock.

  3. 03 Recover

    • Solid carbonFASCarbon™, the retained carbon fraction
    • Liquid streamsRecovered through condensation
    • Process gasesHydrogen and methane

  4. 04 Refine

    Six market products.

    Refining and chemical conversion turn the recovered products into fuels, carbon and chemicals for energy, industry and agriculture.

    Explore the six products

Internal gas reuse

Hydrogen and methane go back to fuel the process

Read the full process description

  1. Feed

    Solid carbonaceous feedstock — coal, lignite, and potentially other hydrocarbons such as oil sands or waste plastics — enters the FASForm™ unit.

  2. Fractionate

    A proprietary thermal and chemical process liberates volatiles, moisture, and contaminants from the solid carbon, separating the feedstock into distinct streams rather than burning it whole.

  3. Refine

    Liquid streams are processed downstream into diesel, naphtha and jet fuel–grade kerosene, while sulfur- and nitrogen-bearing streams are converted into chemical products.

  4. Upgrade

    The remaining solid-carbon stream becomes FASCarbon™, with moisture and selected contaminants removed.

  5. Loop

    Hydrogen and methane go back to fuel the process

Environmental stewardship

Everything accounted for.

01

Design basis

Zero-waste by design

Captured liquid, gas, solid-carbon and byproduct streams are converted into saleable products rather than discharged.

02

Company estimates

Cleaner than combustion

Because the coal isn’t burned, much of its carbon stays locked in FASCarbon™ instead of leaving as CO₂. Sulfur oxide emissions are estimated at roughly 97% below conventional coal combustion.

03

Contaminants

Capture and conversion

Moisture, sulfur, mercury and arsenic are removed from the solid carbon before it ships. Sulfur and nitrogen become sulfuric acid and fertilizer, and airborne mercury emissions are effectively eliminated.

04

Process fuel

The plant fuels itself

Hydrogen and methane released during fractionation fire the plant’s heaters and help upgrade its fuels, minimizing the use of outside natural gas and external energy.

Frontieras embraces a philosophy of responsible environmental stewardship.

When embracing a philosophy of responsible environmental stewardship, Frontieras North America finds it valuable to recognize the difference between “pollution” and “waste.”

In any system where energy is consumed and materials are manufactured, waste is present. In any ecosystem or biological system, for example, organisms naturally generate waste as a byproduct of metabolism. In the construction of a home, building, or city, waste materials are the unused materials left from the construction process.

However, pollution can best be described as the unnecessary production of waste materials. Pollution is caused by the inefficient management of waste - in a world with growing populations, inefficient waste management, and rising levels of environmental pollution, innovative solutions are needed. Humans and animals thrive when there’s sufficient clean air, water, food, and systems to efficiently manage waste. Without a clean environment, humanity will suffer.

Core to Frontieras’ philosophy is the idea that the world’s environmental issues can be solved through technological innovation. Technological innovation allows humanity to expend more energy while producing less waste and pollution.

Frontieras’ patented FASForm™ technology, designed for zero waste, is this kind of innovation.

FASForm™ is the next generation of coal technology, and a major leap forward for the hydrocarbon energy industry as a whole. FASForm™ technology allows for greater extraction of energy, in the form of liquids, solids, and gases, through a process designed for zero waste. It’s a cleaner, more efficient paradigm, and as populations grow and demand for resources increases, FASForm™ is the type of innovation the world needs.

Publicly announced collaborators

Industrial expertise behind FASForm™.

Process technology, engineering, automation and planned operations for the first commercial facility. Each role below is drawn from the company's filed materials and public announcements.