Researchers at the National Institute of Technology Rourkela (NIT Rourkela) have secured a patent for a high-strength composite material developed by recycling coal-mining and industrial waste, with potential applications in road construction for heavy-traffic conditions.
The technology seeks to address two challenges simultaneously, the management of large quantities of mining and industrial waste and the growing need for durable road infrastructure capable of withstanding heavy vehicle traffic.
The research team comprising Prof. K. Umamaheshwar Rao, Professor and Director, Dr. Manoj Kumar Mishra, Professor, and research scholar Dr. Subhasrita Chodhury, PhD graduate, from the Department of Mining Engineering, has secured the patent for the technology..
Turning mining waste into a construction resource
India mines about 1 billion tonnes of raw coal annually, according to the Ministry of Coal, with around 94% coming from surface mining operations. Such operations generate substantial quantities of different types of waste, including coal parting material containing rock and other non-coal materials.
Conventional disposal of this waste puts significant pressure on the environment. The NIT Rourkela team explored the potential of the silica and alumina-rich clay minerals present in coal mine partings for construction applications.
These minerals possess properties such as compressive strength and stiffness, which can potentially be enhanced when combined with suitable industrial additives.
The researchers developed a composite material by combining coal mine parting, fly ash and a binder, and evaluated different formulations to determine the optimum mix for performance.
Prof. K. Umamaheshwar Rao said the technology is particularly relevant to coal-mining regions, where roads frequently carry heavy vehicles transporting mined materials.
“Such roads are exposed to significant loads and repeated traffic, resulting in frequent deterioration,” he said.
Circular economy approach
The technology also demonstrates how waste generated by mining and industrial activities can be redirected towards infrastructure development.
Dr. Manoj Kumar Mishra described the composite as an example of the circular economy principle, noting that it converts two industrial wastes generated in large volumes into a resource with engineering and economic potential.
According to him, the technology could simultaneously address waste-management challenges while supporting indigenous and sustainable infrastructure development.
Field trials planned
The research team plans to move towards pilot-scale field trials to assess the material’s long-term durability and strength under real-world conditions.
The trials are expected to provide further insights into the performance of the composite under actual road conditions, particularly in areas exposed to heavy vehicle movement.
If successfully demonstrated at field scale, the technology could offer coal-mining regions an alternative approach to managing mining and industrial waste while developing road infrastructure designed for demanding traffic conditions.