Optimization of hydrothermal synthesis of pure phase zeolite Na-P1 from South African coal fly ashes

This study was aimed at optimizing the synthesis conditions for pure phase zeolite Na-P1 from three coal fly ashes obtained from power stations in the Mpumalanga province of South Africa. Synthesis variables evaluated were: hydrothermal treatment time (12–48 hours), temperature (100–160°C) and varying molar quantities of water during the hydrothermal treatment step (H2O:SiO2 molar ratio ranged between 0–0.49). The optimum synthesis conditions for preparing pure phase zeolite Na-P1 were achieved when the molar regime was 1 SiO2: 0.36 Al2O3: 0.59 NaOH: 0.49 H2O and ageing was done at 47°C for 48 hours. The optimum hydrothermal treatment time and temperature was 48 hours and 140°C, respectively. Fly ashes sourced from two coal-fired power plants (A, B) were found to produce nearly same high purity zeolite Na-P1 under identical conditions whereas the third fly ash (C) lead to a low quality zeolite Na-P1 under these conditions. The cation exchange capacity for the high pure phase was found to be 4.11 meq/g. Th...