Synthesis of EMT/FAU-type zeolite nanocrystal aggregates in high yield and crystalline form

Valorization of vitreous China waste to EMT/FAU, FAU and Na-P zeotype materials

In this study, Na-X, Na-P, SOD and EMT/FAU zeotype materials have been prepared from vitreous China waste by conventional hydrothermal route and alkaline fusion prior to hydrothermal synthesis. The conventional route has shown its limits in the activation of the waste in the chosen experimental conditions, [NaOH] = 3.5 M and T = 60 °C. The amorphous phase of vitreous China waste plays an important role during the zeolitization process because it easily dissolves into the alkaline solution compared to crystalline phases like quartz and mullite. By the conventional route, Na-X and Na-P1 and SOD zeolites were obtained. The alkaline fusion step using NaOH as mineralizer at 550 °C converted the waste to highly active soluble aluminate and silicate salts. The fused material was mixed with distilled water to have liquid to solid ratio L/S = 5, under vigorous stirring at room temperature for 1 day. The obtained gel with molar composition of 7.0 Na₂O: 1.0 Al₂O₃: 4.8 SiO₂: 209.4 H₂O was converted by hydrothermal crystallization at 60 °C to nanosized EMT/FAU zeotype and geopolymeric amorphous aluminosilicate material. With the increase of fusion time, there is a decrease of the amount of EMT-type zeolite.