Advanced automation, industrial cybersecurity and digital control systems will support Frontieras’ first large-scale FASForm facility in West Virginia

Charleston, West Virginia, 13 August 2026 – Yokogawa has been selected to lead the automation of Frontieras North America’s $850 million FASForm industrial facility in Mason County, West Virginia. The project will place advanced automation, safety systems, and industrial cybersecurity at the center of a facility designed to bring FASForm Solid Carbon Fractionation technology to commercial scale.

As the Main Automation Contractor, Yokogawa will handle far more than the installation of a standard control system. Its role will cover the development of the automation architecture from the early engineering stage through commissioning and startup. The company will integrate production control, safety systems, instrumentation, analytical tools, digital platforms and cybersecurity into a connected operational environment.

The FASForm plant is designed to process around 2.7 million tons of coal each year through a non-combustion conversion process. Instead of burning coal to generate electricity, the technology is intended to separate and process hydrocarbons to create products such as refined liquid fuels, hydrogen, carbon products and industrial chemicals. Frontieras has positioned the facility as the first large-scale commercial application of its FASForm technology.

One of the key technologies supporting the plant will be Yokogawa’s CENTUM VP distributed control system. This platform will help centralize the supervision and control of different industrial processes across the facility. The automation setup will also include a Safety Instrumented System, asset management tools, a plant historian for storing operational data, and systems for operator training.

For a project of this scale, automation will play a much larger role than simply controlling machinery. Since the facility is the first commercial-scale application of the technology, stable operations, process reliability, and the ability to respond to unexpected changes will be important. An integrated automation system can help operators monitor thousands of process variables and use the information to make faster and more informed decisions.

Cybersecurity is another major part of the project. Yokogawa will develop the industrial cybersecurity architecture in line with IEC 62443 SL2 requirements. By including cybersecurity during the engineering and design stages, the project aims to protect connected operational technology systems from the beginning rather than treating security as an addition after installation.

This approach reflects the growing connection between industrial automation and digital technology. Modern plants increasingly depend on connected control systems, data platforms, sensors and asset management tools. While these technologies can improve visibility and efficiency, they also increase the need to protect critical systems and communications.

Construction of the Mason County facility officially began on April 2, 2026. The project is expected to create around 2,000 jobs during construction and approximately 200 permanent positions once the facility becomes operational. The next major challenge will be integrating the control, safety, cybersecurity, and digital systems required to support the plant’s commercial operations.

Yokogawa’s involvement highlights the increasing importance of smart industrial infrastructure in large-scale manufacturing and energy projects. For Frontieras, the real test will be demonstrating that FASForm technology can operate safely, reliably and consistently at commercial scale. If successful, the West Virginia facility could serve as an important model for the company’s future expansion plans across North America.