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Around 25 million tons of coal mine waste rock (CMWR) are stored in many places in Morocco due to coal mining activities. As a result, air and water quality of the neighborhood is polluted and large lands are occupied. This study aimed to investigate the use of an integrated and circular approach based on coal recovery and waste rock recycling. More than 30 drill core samples were taken from the big coal dump reaching a depth of 60 m and analyzed to evaluate the chemical composition variability. Froth flotation was used to recover coal particles using diesel as a collector and Methyl Isobutyl Carbinol as a frother, 100 g/t each. The tailings of coal flotation process (CFT) were used to manufacture fired bricks at a pilot scale. The results of this study highlighted the possibility to valorize the whole waste material toward an objective of zero waste in the future. On a basis of 100t feed, (i) 10-15t can be recovered as high-quality anthracite coal with a calorific value over 7500 kcal/kg using flotation processing at a recovery yield over 80%, (ii) 45-60t can be reused as shales for bricks production with a compressive strength over 16MPa, (iii) 20-30t can be reused as aggregates for concrete production with a compressive strength over 20MPa. The remaining material can be reused as sand. The recovered anthracite can be reused to manufacture coal briquettes or used at it is in the thermal power plant next to the dump site.

Towards an integrated approach for zero coal mine waste storage: solutions based on materials circularity and sustainable resource governance