Experiments on zeolitization were conducted on four synthetic monocationic glasses (Na, K, Ca, or Mg-rich glass) with Si/Al molar ratios of 2.67, similar in acidity to many volcanic glasses of partially zeolitized Italian tuffs. The products of the hydrothermal treatment at 100, 150, and 200°C of single glasses or glass mixtures with deionized H2O or monosaline solutions (NaCl, KCl, CaCl2) were characterized by X-ray diffraction, thermal, microscopic and chemical analyses. Chemical analyses of mother liquors were also performed. Mineral assemblages, containing chabazite, phillipsite, analcime, and K-feldspar, very similar to those found in altered, volcaniclastic alkali-trachytic or trachytic glass deposits were produced. Potassium was essential to chabazite and phillipsite crystallization, although phillipsite was obtained also in Ca-Na mixed systems. Sodium was necessary for analcime formation. Calcium plays only a secondary role in zeolitization, and magnesium does not favor zeolite crystallization but promotes the formation of smectite. Glass composition determines the mineral assemblages obtained and hence in those commonly found in nature.

The level of Fe impurities in 2 well-crystallized kaolinites was modified (by addition or chemical removal treatment) to analyze the Fe influence in the aluminosilicate zeolite synthesis.

The original and modified clays were heat-treated in order to change their reactivity for zeolite A synthesis, and their thermal transformations were studied by X-ray diffraction (XRD), determination of point of zero charge (PZC) and infrared (IR) techniques. It was established that many structural changes took place, regardless of the Fe clay content. Furthermore, the presence of Fe species in alkaline solution or in the solid phase did not seem to greatly influence the zeolite crystallization, because only small differences in the conversion values among samples with different Fe contents were registered. The crystallization process seemed to be related mainly to AI coordination changes produced by the thermal and Fe removal treatments used.

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.