Coal is an important fuel used in boiler furnaces. There are problems like unburnt coal and solid wastes like ash contain arsenic, selenium, chromium and cadmium while using it. In order to avoid all such difficulties, aluminium metal powder in various grain sizes mixed with pulverized coal and burned. aluminium metal powder is one of the pyrotechnics having higher calorific value and low ignition temperature. The thermal behavior of aluminium powder along with coal is recorded in DTA. The collected ashes were tested in Scanning Electron Microscope and X-Ray Diffraction meter. The SEM results show that coal ash is having granular and regular structure. All the particles have a size range from 5 to 8 μm. On the other hand, the aluminium coal mixture ash shows a fibrous matrix and the particles are irregular. In XRD graph, the peaks in the graph show orientation of atoms in particular plane and angle. The coal ash has a lot of peaks, but the maximum count value reaches only to 340.97. However the value of counts reaches a maximum of 1,539.06 for aluminium ash. This denotes high atom orientation in a single lattice plane.