Physicochemical Surface Modification and Characterisation of Coal Fly Ash for Application in Rubber Composites

This study evaluated the capability of coal fly ash (untreated and physicochemically modified) when utilised as a filler in cis-1,4-polyisoprene rubber. Physicochemical modification of the ash was achieved using two techniques: (1) ammonium sulphate roasting followed by controlled aqueous dissolution and (2) sulphuric acid leaching. In addition, the effectiveness of a silane-coupling agent (Si-69) in enhancing the compatibility of untreated and physically modified ash samples with natural rubber was investigated. The ammonium sulphate roasting route increased the surface area and roughness and decreased the particle–particle agglomeration of the fly ash sample. Sulphuric acid treatment decreased the particle–particle agglomeration. However, no increase in surface roughness was observed. The untreated fly ash samples were not significantly reinforcing, and the properties they imparted were inferior to the least reinforcing carbon black. Silane treatment resulted in improved dispersion and wetting of the fly ash in the rubber matrix, leading to improved reinforcement compared to neat rubber. In situ addition of the silane during preparation of the vulcanisates led to composites with better mechanical properties than the composites containing silane-pre-treated fly ash. Composites filled with ammonium sulphate-roasted-and-leached ash performed better than the composites filled with untreated ash and sulfuric acid-leached ash. These findings suggest that modified fly ash holds promise as an effective filler for rubber materials, offering potential environmental and economic benefits by repurposing coal combustion by-products.