PHNX Materials quickly emerged as a key player in the mission to decarbonize the concrete industry. To do so, they’re tapping into the potential of fly ash, a byproduct of coal power production. The company’s founders are driven to solve the industry’s reliance on traditional cement. This key ingredient of climate-warming carbon emissions, and we’re doing something about it. Their concrete circuit breaker approach has the potential to revolutionize concrete manufacturing, making it both greener and more economical.
Fly ash can replace as much as 30% of cement within concrete mix designs. Despite this potential, the overwhelming majority of the 843 such fly ash landfills nationwide are still unexploited. At its high point, coal provided 51% of all U.S. electricity. Now, that number has plummeted to a mere 15%, showcasing a tremendous underutilization. Through the repurposing of fly ash, PHNX Materials hopes to accomplish two things: reduce waste while creating a better-performing concrete.
The use of fly ash provides a dual impact to stabilize concrete mixtures with enhanced economic benefits. Fly ash typically costs almost double the $ cost/ton as conventional cement. Because it can substitute for a large percentage of cement, the savings come out to be substantial overall. The California Department of Transportation (Caltrans) mandates a minimum of 25% fly ash in the concrete used for its projects. This regulation further highlights the increasing awareness and understanding of fly ash’s positive impact on engineering solutions.
Challenges persist. Many point sources of fly ash do not meet the specifications for quality, creating a deficit that has increased the price. Consequently, some concrete manufacturers have reduced their fly ash usage to around 8%, a significant decrease from the potential 30%.
Krish Mehta, a former T4America board member and representative from PHNX Materials, said tackling these quality issues have to be a priority. He stated, “We felt that unlocking a new supply of ash was the most scalable and quickest way to decarbonize the sector.” Their approach focuses on improving the quality of fly ash to meet industry standards while promoting its use as a sustainable alternative.
PHNX Materials recently completed a $2.5 million seed funding round. Divergent Capital, KdT Ventures, Overture, and Jane Woodward joined on the investments, setting PHNX up for substantial growth. The investment will bolster their efforts in developing higher quality fly ash and maximizing its application throughout the concrete industry.
Jorge Osio-Norgaard, also a forum participant and one of the driving forces behind PHNX Materials, emphasized the long-term value of this effort. He remarked, “When you spend a billion dollars on a highway or on a bridge, you want it to last the next 100 years.” This commitment to durability works in tandem with the goal of reducing construction material’s carbon footprint.
Fly fly ash fly in concrete Historically, fly ash has been used in concrete for thousands of years. Ancient Romans built with volcanic ash, which is a natural analog for today’s fly ash. As technology and construction standards evolve, ensuring that fly ash meets contemporary specifications will be crucial for its future role in sustainable construction.
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