A sustainable multi-zeolite synthetic framework from a single natural clay: CO2/H2O adsorption performance and life cycle assessment benefits

Abstract

A novel sustainable synthesis strategy for producing a range of structurally distinct zeolites, specifically Zeolite 4A, Zeolite 13X, and Zeolite Y, is presented. This method avoids organic templates (commonly used for many high-silica zeolites such as ZSM-5, Beta, or high-silica Y) and directly produces Zeolite 4A, Zeolite 13X, and Zeolite Y from natural bentonite clay without the need for synthetic silica or alumina sources and thus offers a much more environmentally-benign production strategy than existing commercial synthetic routes. By systematically tuning alkaline fusion conditions and hydrothermal crystallization parameters, selective zeolite phase formation is achieved: lower fusion temperatures and NaOH/clay ratios favor the formation of LTA-type Zeolite 4A, while higher values promote the formation of FAU-type Zeolite 13X and Zeolite Y. The synthesized zeolites demonstrated structural characteristics and adsorption performance comparable to their commercial counterparts. Zeolite 13X exhibited the highest CO₂ adsorption capacity, attributed to its elevated microporosity and sodium content, while Zeolite Y showed enhanced hydrothermal stability and reduced water affinity, resulting from its higher Si/Al ratio and lower cation density. Water vapor adsorption isotherms and repeated cycling tests revealed clear differences in hydrothermal stability between the synthesized zeolites. A cradle-to-gate life cycle assessment (LCA), performed for Zeolite 13X as a representative product, revealed a ∼90% reduction in global warming potential (2.48 vs. 24.25 kg CO₂ eq. per kg), over 95% lower cumulative energy demand, and significantly decreased ecotoxicity and human toxicity indicators when compared to conventional chemical synthesis. Additionally, cost-oriented economic analysis showed that the clay-based synthesis route reduces the production cost of Zeolite 13X by approximately 33% compared to conventional chemical synthesis. Overall, this work provides a mechanistically informed, environmentally friendly framework for the phase-selective synthesis of industrially relevant zeolites from natural clay.