Production of kaolin for the paper-coating industry in the Brazilian Amazon region generates large amounts of waste, most of which is kaolinite. It is known that such materials can be used to synthesize zeolites. The use of kaolin waste for zeolite synthesis could, in principle, help social and economic development while providing valuable materials for industry. Additionally, there is a significant environmental appeal if such wastes could be used instead of new raw materials.

This study focused on the production of zeolite A. Samples of the raw material were first calcined (700ºC/2 h) to obtain metakaolinite for further reaction with NaOH solution. Different parameters were evaluated to optimize the synthesis conditions of zeolite A. The results showed that zeolite A with a large degree of structural order was generally obtained as the only zeolitic product. The following synthesis conditions were used: temperature 110ºC, time 24 h and a Na/Al ratio of 1.36. Hydroxysodalite was also obtained under specific conditions.

The present work deals with the hydrothermal synthesis of Na zeolites (Na-A, Na-X and Na-P) and hydroxysodalite using kaolinite calcined at 650°C as starting material. The focus was on definition of the most favourable conditions for the synthesis of zeolite Na-A and Na-X from metakaolin in order to economize on both energy (i.e. synthesis temperatures) and reaction time and to enlarge the field of pure and isolated synthesized phases. Metakaolin was mixed with calculated amounts of NaOH solution and sodium silicate and five sets of experiments were carried out at ambient pressure and 68±0.1°C varying the SiO2/Al2O3 ratio from 2.2 to 7. Optimal conditions for crystallization of Na-A zeolite from kaolinite were reached with a SiO2/Al2O3 ratio of 2.2 plus 4 M NaOH without adding sodium silicate; transformation into hydroxysodalite develops after ∼8 h. For SiO2/Al2O3 ratios between 4 and 7, crystallization of the separate Na-X zeolite phase could be achieved and transformation into Na-P and hydroxysodalite occurred after 382 h and 190 h, respectively. For SiO2/Al2O3 ratios between 5 and 6, transformation of metakaolin into Na-X plus Na-A, hydroxysodalite and Na-P occurred, and the field within which Na-A and Na-X zeolite exists overlapped that of the other zeolites.

The products of synthesis were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), inductively coupled plasma optical emission spectrometry (ICP-OES), infrared spectroscopy (IR) and thermal analyses (TG-DTG-DTA).

Obtaining pure Na-A and Na-X zeolite from kaolinite treated at low metakaolinitization temperature (650°C) and low hydrothermal synthesis temperature (68°C) represents a considerable economic advantage in terms of both energy and time.

An experimental investigation was conducted on the alkali activation of a kaolinitic clay using an alkaline mixture composed of hydrated lime (Ca(OH)2) and sodium carbonate (Na2CO3) solution. The Ca(OH)2/Na2CO3 alkaline mixture was developed to overcome the high cost and chemical aggression associated with classical alkaline solutions. The mineralogical composition and microstructure of the alkaline mixture and alkali-activation products were studied using X-ray diffraction, attenuated total reflectance-Fourier transform infrared spectroscopy, thermogravimetric analysis and energy-dispersive X-ray-scanning electron microscopy techniques. Pirssonite (Na2Ca(CO3)2·2H2O), calcite (CaCO3), and sodium hydroxide (NaOH) formed as a result of mixing of Ca(OH)2 with Na2CO3. The alkali activation of natural clay with the Ca(OH)2/Na2CO3 alkaline mixture produced a binding agent identified as hydroxysodalite phase (Na8Al6Si6O24(OH)2·4H2O) when pure kaolinite was used, and cancrinite carbonate (Na6Ca1.5[Al6Si6O24](CO3)1.5·1.8H2O) when kaolinitic clay with high a calcite content was used. The mechanical strength of the binder developed was evaluated on cylindrical specimens containing granite waste as a filler material under dry and soaked conditions. The classical NaOH activator was used for comparison. For specimens produced using a Ca(OH)2/Na2CO3 mixture as the alkaline activator, the recorded strength valuewas 21 MPa which was 35% less than that achieved by the classical NaOH solution. Durability tests on samples soaked in water for 24 h showed a reduction in strength from 34 to 22 MPa for specimens prepared with NaOH solution, and from 21 to 11 MPa for the specimens prepared with a Ca(OH)2/Na2CO3 alkaline mixture.