Energy demand is increasing all over the world, and to fulfill this need, more energy is required to be produced. Coal power plants produce around 39% of energy, but during energy production, these coal power plants also generate waste in the form of coal fly ash (CFA). The reuse of CFA is the only solution to control this waste; fly ash can be used in different products. Therefore, this study utilizes CFA with rubber as filler materials in the rubber industry. There are different techniques (such as nozzle design technology, air classifier, and optimization of CFA to convert crushed fly ash into valuable microparticles. Treated CFA is applied to produce medium voltage insulated cables and fire resistance cables with different kinds of rubber, such as styrene–butadiene and Ethylene–propylene. The study found that by applying CFA in insulated cables, the elongation at break increased by 50%, and volume resistance 2.2 × 1016 Ω·cm, insulation resistance increased 70% by using CFA with magnesium in the recipe of insulated cables. The CFA increased the collection rate of cleaning by 30% using this technology, and product life expectancy increased by 5–20%.

Coal power plants are the major contributor of electricity but these power plants are also producing waste in the form of coal fly ash (CFA). However, it can cause high risk of environmental pollution and pulmonary diseases in humans. Plastic waste is also a problematic waste for many countries in terms of its reuse and recycling. Therefore, this study aims to reuse the waste product (CFA) of coal power plants in rubber conveyer belt instead of calcium carbonate or talcum powder and in recycling of plastic propylene as bonding filler material instead of barium sulfate to increase the durability of plastic products and reduce cost, CFA waste and plastic waste. For this purpose, CFA was treated by different pulverization techniques for the production of conveyor belt. The study found that the most favorable technique was shear based pulverization technique. Application of CFA with rubber was compared with two different chemicals (calcium carbonate and talcum powder) and found that the elongation at break of conveyor belt was 35% increased and abrasion volume was 64% reduced by using treated CFA. Furthermore, CFA was used in molten mass of plastic instead of barium sulfate and the results showed that the use of CFA has improved the dimensional stability of plastic material reducing the cost per ton by 2410 CNY. The study concluded that the performance was increased by applying CFA with a reduction in price as compared to other chemicals.