Synthesis of LTA zeolite beads using alum sludge and silica rich wastes

Abstract

This study successfully recycled alum sludge with either lithium slag or bottle glass to make high purity zeolite LTA beads. The basic synthesis approach was to fuse the waste material with sodium hydroxide then complete hydrothermal crystallization. Separate fusion of individual wastes promoted zeolite LTA formation compared to combined fusion. Preferred synthesis conditions were: 10 Na2O:Al2O3:2.5 SiO2:300 H2O; hydrothermal temperature = 80 °C; time = 5 h. Zeolite LTA purity was between 80 and 85 wt% from the two waste combinations. Use of pseudoboehmite and carboxymethyl cellulose favoured granulation/extrusion/spheronization of zeolite LTA powder. However, the beading process decreased calcium exchange capacity (CEC) from 99.5 to 37 mg Ca2+/g for alum sludge + lithium slag and from 64.5 to 37 mg Ca2+/g for alum sludge + waste glass. Additionally, when using 20 wt% pseudo-boehmite as a binder the ion-exchange equilibrium time increased from 60 to 300 min. The importance of not only making zeolite powder from waste materials but also to extend studies to shaped forms was evident. It is recommended that future studies should also focus on making extrudates or beads as these are the forms used commercially.