Abstract
A simple mixing-pressing followed by thermal curing and pyrolysis process was used to upcycle coal waste into high-value composites. Three coal wastes of different physicochemical properties were investigated. The hypothetical mechanisms of bonding between the coal particles and the preceramic polymer are presented. The textural properties of the coals indicated that the lowest volatile coal waste (PCD) had a dense structure. This limited the diffusion and reaction of the preceramic polymer with the coal waste during pyrolysis, thereby leading to low-quality composites. The water contact angles of the composites up to 104° imply hydrophobic surfaces, hence, no external coating might be required. Analysis of the carbon phase confirmed that the amorphous carbon structure is prevalent in the composites compared to the coal wastes. The dc volume resistivity of the composites in the range of 22 to 82 Ω-cm infers that the composites are unlikely to suffer electrostatic discharge, which makes them useful in creating self-heating building parts. The leached concentrations of heavy metal elements from the composites based on the end-of-life scenario were below the Toxicity Characteristic Leaching Procedure regulatory limits. Additionally, the release potential or mobility of the metals from the composites was not influenced by the pH of the eluants used. On the basis of the reported results, these carbon/ceramic composites show tremendous prospects as building materials due to these properties.