Selective Synthesis of FAU- and CHA-Type Zeolites from Fly Ash: Impurity Control, Phase Stability, and Water Sorption Performance

Fly ash from coal-fired power plants is a promising precursor for zeolite synthesis due to its aluminosilicate-rich composition. However, its direct utilization is often limited by impurities and a low silicon-to-aluminum ratio (SAR). This study demonstrates the conversion of Class C fly ash from the Soma thermal power plant (Turkey) into FAU- and CHA-type zeolites through optimized acid leaching and hydrothermal synthesis. Acid treatment increased the SAR from 1.33 to 2.85 and effectively reduced calcium-, sulfur-, and iron-bearing impurities. The SAR enhancement by acid leaching was found to be reproducible among Class C fly ashes, whereas Class F materials exhibited a limited response due to their acid-resistant framework. Subsequent optimization of alkaline fusion-assisted synthesis enabled selective crystallization of FAU and CHA, while GIS and MER appeared under prolonged crystallization or higher alkalinity. SEM revealed distinct morphologies, with MER forming rod-shaped clusters, and CHA exhibiting disc-like aggregates. Water sorption analysis showed superior uptake for metastable FAU (~23 wt%) and CHA (~18 wt%) compared to stable GIS and MER (~12–13 wt%). Overall, this study establishes a scalable and sustainable route for producing high-performance zeolites from industrial fly ash waste, offering significant potential for adsorption-based applications in dehumidification, heat pumps, and gas separation.