Production of Granulated NaP Zeolite without Binder

Possibility was examined of synthesizing zeolites granulated without a binder with the use of a preliminary ultrasonic treatment of the suspension at a frequency of 22 kHz from mixtures of sodium metasilicate and aluminum and silicon oxides with various Si: Al ratios. It was found that, after the preliminary treatment, extrusion of grains, and calcination at 650°C, crystalline phases Na₆Al₄Si₄O₁₇, Na₈Al₄Si₄O₁₈, Na₂Al₂O₄, and Na₂SiO₃ phases are formed in the sample with Si: Al = 1. These phases are precursors for synthesis of NaA and NaP zeolites and sodalite via hydrothermal crystallization in a NaOH solution with concentration of 2 M. Upon a similar treatment of a sample with Si: Al = 2, there are crystalline phases α- and β-Na₂Si₂O₅, from which only NaP zeolite is formed in the course of crystallization. The hydrothermal crystallization in a 6 M alkali solution yields sodalite, irrespective of the Si: Al ratio. It was shown that an ultrasonic treatment gives a gel-like system at Si: Al = 1 and a powdered material at Si: Al = 2, which yields by the end of synthesis samples with cactus-like or wool-like morphology, respectively.