In the north of Brazil large mineral reserves are found, which have been exploited in recent decades typically generating large volumes of waste to the environment. In the specific case of the kaolin is the main product exported is for paper coating (commodity) with low value. Its production also generates a massive waste composed mainly of high purity kaolinite, but with no specification to cover paper, being discarded or used in other less noble application. As zeolites are more noble materials and present silica and alumina, one of the goals of this work was the development of the production process of the zeolite analcime from kaolin waste, diatomite and sodium hydroxide solution. In the other hand, the methods described for obtaining zeolites are developed in an alkaline medium, typically using an excess of sodium hydroxide in the reaction, causing environmental and economic problems. The synthesis process of zeolite analcime semi-continuous is described, using excess of sodium hydroxide to be recovered and reused in a new process cycle. The process consisted in five consecutive cycles in an autoclave by reaction of calcined kaolin, diatomaceous earth as a source of additional silica, aqueous solution of sodium hydroxide, and fresh sodium hydroxide solution, and recycled. The reaction process was developed at 210 °C for 24 h. The product obtained at the end of each cycle was analcime zeolite characterized by XRF, XRD, DTA / TG, SEM. The production process of analcime showed high yield and reuse of sodium hydroxide through recycle to be technically feasible.
zeolite; analcime; kaolin; synthesis
