ZnO@polyaniline/coal nanocomposite (ZnO@PANI/C) was synthesized and characterized by different analytical techniques as potential enhanced photocatalyst for the successful oxidation of Congo red dye (CR) into eco-friendly end-products. The investigated CR concentration (5 mg/L) was completely decolorized after 120 min, 100 min, 80 min, and 40 min after the incorporation of ZnO@PANI/C dosages at 0.2 g/L, 0.3 g/L, 0.4 g/L, and 0.5 g/L, respectively. The synergetic studies demonstrate a significant impact of the integrated components (coal, polyaniline (14.2 % oxidation of CR), ZnO (21.6 % oxidation of CR), 43.7 % (PANI/C oxidation of CR), and 64.3 % (ZnO/C oxidation of CR)) on the catalytic activity of ZnO@PANI/C (100 % oxidation of CR), which is higher than that of the individual components. The investigation of TOC content reflects that the complete mineralization can be detected after 100 min and validates the formation of different species of intermediates started by sodium-3-(phenyl diazenyl) naphthalene-1-sulfonate until detecting ethyl benzene. The findings of the oxidizing trapping tests demonstrate the controlling impact of the hydroxyl radicals as the oxidation in the presence of its trapping reagent (Isopropanol) declined to 8.6 %. The oxidation pathway of CR over ZnO@PANI/C involved a progressive series of decarboxylation and dihydroxylation ended by ethylbenzene, which in turn produced nontoxic products such as H2O and CO2. The eco-toxicity tests reflect the efficiency of the photo-oxidation of CR contaminants by ZnO@PANI/C in reducing acute toxicity (LC50 and EC50 > 100) and chronic (ChV > 10) toxicities of CR dye after 60 min of remediation.