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Existing methods for disposing of coal industry waste do not ensure their effective use in the production of building materials, leading to the accumulation of waste dumps and worsening environmental conditions. This research addresses the performance limitations of traditional ceramics by proposing the integration of fine-grained coal mining waste as a primary raw material component. This strategy serves a dual purpose: resolving waste disposal concerns and enhancing ceramic properties through structural modification. The study evaluates the key physicochemical properties of such waste and their effect on material quality. It was determined that the inclusion of fine waste fractions necessitates optimized firing parameters to counteract reductions in density and strength. Empirical models defined the relationship between waste fineness, sintering temperature, and mechanical properties. A specialized semi-dry pressing method was engineered to minimize strength degradation and ensure the production of consistent ceramic blocks. The overarching goal of this technological approach is to achieve cost reduction and heightened product reliability via an optimized synthesis of raw materials and thermal regimes. Application of this method using Eastern Donbass coal waste is envisaged to ensure economic viability while upgrading the technical profile of the resulting construction materials.
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10. Kotlyar V.D., Nebezhko Yu.I., Semenova M.Yu. Molding properties of clay mixtures in the soft mud brick manufacture. Construction Materials and Products. 2024. 7. P. 5. DOI: 10.58224/2618-7183-2024-7-1-5
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12. Yavruyan K., Kotlyar V. Estimation of Chemical and Mineral Composition, Structural Features, and Pre-Firing Technological Properties of Waste Coal Heaps for Ceramic Production. Buildings. 2024. 14. P. 1905. DOI: 10.3390/buildings14071905
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14. Yavruyan Kh.S., Kotlyar V.D., Gaishun E.S. Medium-fraction materials for processing of coal-thread waste drains for the production of wall ceramics. Materials Science Forum. 2018. 931. P. 532 – 536.
15. Yavruyan Kh.S., Sarukhanov E.M. The production of high-performance ceramic stones based on the products of processing of coal dumps. Construction Materials and Products. 2024. 7. P. 4. DOI: 10.58224/2618-7183-2024-7-4-4
16. Kongar-Syuryun Ch.B., Khairutdinov A.M., Dengaev A.V., Abdulrakhman B. Study of mechanical characteristics of a filling composite created on the basis of coal mining waste. Coal. 2025. No. 3. P. 145 – 148. DOI: 10.18796/0041-5790-2025-3-145-148
17. Gaishun E.S., Filippova A.A., Gaishun A.S., Kotlyar V.D. [et al.] Promising raw materials based on waste heaps of the Eastern Donbass for the production of ceramic stones. Vestnik of the Volgograd State University of Architecture and Civil Engineering. Series: Construction and Architecture. 2020. No. 1. P. 118 – 125.
18. Kostenko V., Bohomaz O., Tavrel M., Hlushko I., Kostenko T. Physical and mechanical properties of burnt-out coal mine waste heaps. IOP Conference Series: Earth and Environmental Science. 2024. 1415. P. 012009. DOI: 10.1088/1755-1315/1415/1/012009.
19. Luo Y., Wu Y., Ma S., Zheng S., Chu P.K. An eco-friendly and cleaner process for preparing architectural ceramics from coal fly ash: Pre-activation of coal fly ash by a mechano-chemical method. Journal of Cleaner Production. 2019. 214. P. 419 – 428.
20. Eckel Z.C., Zhou C., Martin J.H., Jacobsen A.J., Carter W.B., Schaedler T.A. Additive manufacturing of polymer-derived ceramics. Science. 2016. 351. P. 58 – 62.
21. Kumaneeva M.K., Sheveleva O.B., Zonova O.V. Production waste management in the coal industry: resource and environmental aspect. Coal. 2024. 2. P. 74 – 78. DOI: 10.18796/0041-5790-2024-2-74-78
22. Artemov I.A. Mineralogical and petrographic zoning of burnt mountain dumps of coal mines (Eastern Donbass). Geology and Geophysics of the South of Russia. 2025. 15 (2). P. 155 – 165. DOI: 10.46698/VNC.2025.14.75.001
23. Eterigho-Ikelegbe O., Trammell R., Bada S. Preparation and characterisation of ceramic composites from South Africa coal discard. Construction and Building Materials. 2021. 302. P. 124164. DOI: 10.1016/j.conbuildmat.2021.124164
24. Seregin A.I. Processing of the coal slimes into the commodity products by the non-traditional physical and chemical influence: diss. … candidate of technical sciences. Moscow, FGUP IGI, 2009. 183 p.
25. Chikisheva T.A., Komarova A.G., Turetskaya N.Yu. Mineralogical and technological assessment of waste from the Kuzbasskaya Central Processing Plant (Kemerovo Region). Herald of Geosciences. 2024. 9. P. 28 – 34. DOI: 10.19110/geov.2024.9.4
26. Danek T., Jelinek J., Thomas J. Material of Burned Coal Wastes Spoil Heaps As Source of Mullite for Ceramic Industry. MATEC Web of Conferences. 2015. 26. P. 01004. DOI: 10.1051/matecconf/20152601004
27. Chop H., Arnold B.J. Utilization of Coal Wastes for the Production of Ceramic Materials: A Review. Mining, Metallurgy & Exploration. 2025. 42. P. 1001 – 1023. DOI: 10.1007/s42461-025-01195-3
2. Kolomenskiy G.Yu., Gipich L.V., Kolomenskaya V.G., Savitskiy D.V. Coal wastes of Eastern Donbass as technogenic mineral raw materials. Review information. Moscow: Geoinformcentre, 2002. 51 p.
3. Stolboushkin A.Yu. Perspective direction of development of building ceramic materials from low-quality raw materials. Construction Materials. 2018. 4. P. 24 – 28.
4. Rakhimova G., Stolboushkin A., Vyshar O., Stanevich V., Rakhimov M., Kozlov P. Strong Structure Formation of Ceramic Composites Based on Coal Mining Overburden Rocks. Journal of Composites Science. 2023. 7. P. 209. DOI: 10.3390/jcs7050209
5. Stolboushkin A.Yu. Wall ceramic materials of the matrix structure on the basis of non-flowing low-plastic technogenic and natural raw materials: diss. … doctor of technical sciences: 05.23.05. Tomsk, 2015. 395 p.
6. Stolboushkin A.Yu., Vereshchagin V.I., Fomina O.A. Phase Composition of the Core–Shell Transition Layer in a Construction Ceramic Matrix Structure Made from Non-Plastic Raw Material with Clay Additives. Glass and Ceramics. 2019. 76. P. 16 – 21.
7. Kotlyar V.D., Talpa B.V., Teryokhina Y.V., Kotlyar A.V. Technogenic raw materials for the production of construction materials: textbook in 2 parts. Part 1. Rostov n/D: Rostov State Construction University, 2014. 130 p.
8. Kotlyar V.D., Talpa B.V., Teryokhina Y.V., Kotlyar V.D. Technogenic raw materials for the production of construction materials: a manual in 2 parts. Part 2. Rostov n/D: Rostov State Construction University, 2014. 96 p.
9. Kotlyar V.D., Ustinov A.V., Terekhina Yu.V., Kotlyar A.V. Features of the coal firing process for the production of wall ceramics. Tekhnika i Tekhnologiya Silikatov [Technique and Technology of Silicates]. 2014. 21 (4). P. 8 – 15.
10. Kotlyar V.D., Nebezhko Yu.I., Semenova M.Yu. Molding properties of clay mixtures in the soft mud brick manufacture. Construction Materials and Products. 2024. 7. P. 5. DOI: 10.58224/2618-7183-2024-7-1-5
11. Kotlyar V.D., Teryokhina Y.V., Kotlyar A.V. Method of testing stone-like raw materials for the production of wall products of compression moulding. Construction Materials. 2014. 4. P. 24 – 27.
12. Yavruyan K., Kotlyar V. Estimation of Chemical and Mineral Composition, Structural Features, and Pre-Firing Technological Properties of Waste Coal Heaps for Ceramic Production. Buildings. 2024. 14. P. 1905. DOI: 10.3390/buildings14071905
13. Kotlyar V., Yavruyan K. Thin issues products of processing waste heaps as raw materials for ceramic wall products. MATEC Web of Conferences. 2017. P. 05013.
14. Yavruyan Kh.S., Kotlyar V.D., Gaishun E.S. Medium-fraction materials for processing of coal-thread waste drains for the production of wall ceramics. Materials Science Forum. 2018. 931. P. 532 – 536.
15. Yavruyan Kh.S., Sarukhanov E.M. The production of high-performance ceramic stones based on the products of processing of coal dumps. Construction Materials and Products. 2024. 7. P. 4. DOI: 10.58224/2618-7183-2024-7-4-4
16. Kongar-Syuryun Ch.B., Khairutdinov A.M., Dengaev A.V., Abdulrakhman B. Study of mechanical characteristics of a filling composite created on the basis of coal mining waste. Coal. 2025. No. 3. P. 145 – 148. DOI: 10.18796/0041-5790-2025-3-145-148
17. Gaishun E.S., Filippova A.A., Gaishun A.S., Kotlyar V.D. [et al.] Promising raw materials based on waste heaps of the Eastern Donbass for the production of ceramic stones. Vestnik of the Volgograd State University of Architecture and Civil Engineering. Series: Construction and Architecture. 2020. No. 1. P. 118 – 125.
18. Kostenko V., Bohomaz O., Tavrel M., Hlushko I., Kostenko T. Physical and mechanical properties of burnt-out coal mine waste heaps. IOP Conference Series: Earth and Environmental Science. 2024. 1415. P. 012009. DOI: 10.1088/1755-1315/1415/1/012009.
19. Luo Y., Wu Y., Ma S., Zheng S., Chu P.K. An eco-friendly and cleaner process for preparing architectural ceramics from coal fly ash: Pre-activation of coal fly ash by a mechano-chemical method. Journal of Cleaner Production. 2019. 214. P. 419 – 428.
20. Eckel Z.C., Zhou C., Martin J.H., Jacobsen A.J., Carter W.B., Schaedler T.A. Additive manufacturing of polymer-derived ceramics. Science. 2016. 351. P. 58 – 62.
21. Kumaneeva M.K., Sheveleva O.B., Zonova O.V. Production waste management in the coal industry: resource and environmental aspect. Coal. 2024. 2. P. 74 – 78. DOI: 10.18796/0041-5790-2024-2-74-78
22. Artemov I.A. Mineralogical and petrographic zoning of burnt mountain dumps of coal mines (Eastern Donbass). Geology and Geophysics of the South of Russia. 2025. 15 (2). P. 155 – 165. DOI: 10.46698/VNC.2025.14.75.001
23. Eterigho-Ikelegbe O., Trammell R., Bada S. Preparation and characterisation of ceramic composites from South Africa coal discard. Construction and Building Materials. 2021. 302. P. 124164. DOI: 10.1016/j.conbuildmat.2021.124164
24. Seregin A.I. Processing of the coal slimes into the commodity products by the non-traditional physical and chemical influence: diss. … candidate of technical sciences. Moscow, FGUP IGI, 2009. 183 p.
25. Chikisheva T.A., Komarova A.G., Turetskaya N.Yu. Mineralogical and technological assessment of waste from the Kuzbasskaya Central Processing Plant (Kemerovo Region). Herald of Geosciences. 2024. 9. P. 28 – 34. DOI: 10.19110/geov.2024.9.4
26. Danek T., Jelinek J., Thomas J. Material of Burned Coal Wastes Spoil Heaps As Source of Mullite for Ceramic Industry. MATEC Web of Conferences. 2015. 26. P. 01004. DOI: 10.1051/matecconf/20152601004
27. Chop H., Arnold B.J. Utilization of Coal Wastes for the Production of Ceramic Materials: A Review. Mining, Metallurgy & Exploration. 2025. 42. P. 1001 – 1023. DOI: 10.1007/s42461-025-01195-3
Yavruyan Kh. S. Improving the operational characteristics of wall ceramic products through the use of coal waste heap processing materials. Construction Materials and Products. 2025. 8 (6). 3. https://doi.org/10.58224/2618-7183-2025-8-6-3