Semipilot Scale Synthesis of Zeolite A from Kaolin Filler: Process Optimization with Boiler Steam, Mathematical Modeling, and Cu 2+ Adsorption

High Resolution Image Download MS PowerPoint Slide This work reports the semipilot-scale synthesis of zeolite A using a boiler as an unconventional thermal energy source and Amazonian kaolin filler as the Si/Al source. By enabling more effective heat transfer and reducing reaction times without compromising product quality, the proposed method enhances conventional synthesis routes. Zeolite A formation was confirmed by structural characterization using XRD, XRF, TG/DTA, and SEM. Adsorption experiments of Cu 2+ ions were conducted at 25, 50, and 75 °C, showing maximum adsorption capacities of 107.5, 124.1, and 119.9 mg g –1, respectively, demonstrating high metal removal performance. Langmuir, Freundlich, and Sips isotherms were used to model the adsorption equilibrium, and parameters were estimated via a Markov chain Monte Carlo method. The Langmuir isotherm provided the best fit at 25 °C, whereas the Sips isotherm showed superior performance at 50 and 75 °C, as indicated by both the coefficient of determination and the Bayesian Information Criterion. The results highlight the potential of this route as a scalable and efficient alternative for zeolite A synthesis, capable of producing high-quality material in a reduced synthesis time and demonstrating effective performance in environmental applications.