Valorization of coal fly ash into nanozeolite by sonication-assisted hydrothermal method

The study aimed at the recycle and reuse coal fly ash (CFA) via a fast green method. Increasing dependence of coal in power sector results in increased production of CFA, the disposal of which is a major environmental issue. Sonication assisted hydrothermal (UAH) treatment has been employed to convert this CFA into versatile nanozeolite X (NZX) from CFA. The effect of CFA/NaOH, fusion temperature, fusion time and ultrasonication time were investigated. Initial precursor CFA and the synthesized NZX were characterized by XRF, XRD, FESEM, TEM, and FTIR analysis. UAH treatment produced NZX in shorter crystallization time than conventional hydrothermal (CH) method. The particle size of UAH-NZX were obtained from FESEM, BET, TEM analysis as 22-27 nm, 24.36 nm, and 2-5 nm respectively. Average crystal size of UAH-NZX was 21.58 nm as calculated using Scherrer's equation. The optimized condition for the UAH synthesis of NZX was found as CFA/NaOH ratio of 1.25, fusion temperature of 550 °C, fusion time of 1.5 h, and ultrasound time of 20 min. The characteristics of UAH-NZX zeolite was compared with CH-NZX and commercial zeolite X (CZX). The pure NZX was formed by UAH technique with 20 min ultrasound, followed by 6 h hydrothermal treatment at room temperature whereas CH technique took 96 h of hydrothermal digestion at 120 °C. The optimized CEC value of NZX, conventional hydrothermal zeolite X (CH-ZX), and CZX are 428 mmol/100 g, 242 mmol/100 g, and 293 mmol/100 g respectively. The UAH method produced NZX at shorter time with less consumption of energy than CH method with nanozeolite with higher CEC and surface area (797.53 m²/g) than both CH-NZX and CZX. The nanoscale zeolite X can be used efficiently as ion exchanger as well as adsorber.