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Energy demand is increasing all over the world, and to fulfill this need, more energy is required to be produced. Coal power plants produce around 39% of energy, but during energy production, these coal power plants also generate waste in the form of coal fly ash (CFA). The reuse of CFA is the only solution to control this waste; fly ash can be used in different products. Therefore, this study utilizes CFA with rubber as filler materials in the rubber industry. There are different techniques (such as nozzle design technology, air classifier, and optimization of CFA to convert crushed fly ash into valuable microparticles. Treated CFA is applied to produce medium voltage insulated cables and fire resistance cables with different kinds of rubber, such as styrene–butadiene and Ethylene–propylene. The study found that by applying CFA in insulated cables, the elongation at break increased by 50%, and volume resistance 2.2 × 1016 Ω·cm, insulation resistance increased 70% by using CFA with magnesium in the recipe of insulated cables. The CFA increased the collection rate of cleaning by 30% using this technology, and product life expectancy increased by 5–20%.

Treatment of Coal Fly Ash and Environmentally Friendly Use with Rubber in Cable Wires as Insulation Material