Effect of ultrasound energy on the zeolitization of chemical extracts from fused coal fly ash

• Ultrasonic energy produces zeolite from CFA at lower temperatures.
• Ultrasonic dramatically reducing the synthesis time.
• Ultrasonic produces zeolite with high phase purity.
• Ultrasonic produces zeolite with high crystallinity.

This paper investigates the effects of ultrasound (UTS) energy at different temperatures on the zeolitization of aluminosilicate constituents of coal fly ash. UTS energy irradiated directly into the reaction mixture utilizing a probe immersed into the reaction mixture, unlike previously reported works that have used UTS baths. Controlled synthesis was also conducted at constant stirring and at the same temperatures using conventional heating. The precursor reaction solution was obtained by first fusing the coal fly ash with sodium hydroxide at 550 °C followed by dissolution in water and filtration. The synthesized samples were characterized by XRF, XRD, SEM and TGA. The crystallinity of crystals produced with UTS assisted conversion compared to conventional conversion at 85 °C was twice as high. UTS energy also reduced the induction time from 60 min to 40 min and from 80 min to 60 min for reaction temperatures of 95 °C and 85 °C, respectively. Prolonging the UTS irradiation at 95 °C resulted in the conversion of zeolite-A crystals to hydroxysodalite, which is a more stable zeolitic phase. It was found that at 85 °C coupled with ultrasound energy produced the best crystalline structure with a pure single phase of zeolite-A. It has been shown that crystallization using UTS energy can produce zeolitic crystals at lower temperatures and within 1 h, dramatically cutting the synthesis time of zeolite.