Rare earth elements (REE) have been recognised as critical raw materials, crucial for many clean technologies. As the gap between their global demand and supply increases, the search for their alternative resources becomes more and more important, especially for the countries which depend highly on their import. Coal fly ash (CFA), which when not utilised is considered waste, has been regarded as the possible source of many elements, including REE. Due to the increase in the energy demand, CFA production is expected to grow, making research into the use of this material a necessity. As Poland is the second biggest coal consumer in the European Union, the authors have studied different coal fly ashes from ten Polish power plants for their rare earth element content. All the fly ashes have a broadly similar distribution of rear earth elements, with light REE being dominant. Most of the samples have REE content relatively high and according to Seredin and Dai (Int J Coal Geol 94: 67–93, 2012) classification can be considered promising REE raw materials.

This paper presents a sub-pilot scale process of synthesis of Na-P1 zeolite from the coal fly ash. After establishing the appropriate synthesis conditions (20 kg of fly ash, 12 kg of NaOH, 90 dm³ of water, the reaction temperature: 80 °C and reaction time: 36 h), the high-purity (81 wt%) Na-P1 zeolite product was obtained. Its chemical, mineralogical, and textural properties were determined (by means of XRD, XRF, SEM–EDS and ASAP 2020). The synthesized material has a specific BET surface area (88 m²/g) c.a. six times higher than the fly ash from which it has been derived (15 m²/g). The pore-size distribution indicates a mesoporous character of the obtained zeolite, with the following pores size contents: micropores (2.76 %), mesopores (61.81 %), and macropores (35.43 %). The presented technological/production line is fully automated and allows to regulate the conditions of the synthesis process, therefore different types of zeolite materials (including: Na-X, Linde-A, and Na-P1) can be obtained using the same equipment.

In this paper, we present the possibility of using fly ash to produce synthetic zeolites. The synthesis class F fly ash from the Stalowa Wola SA heat and power plant was subjected to 24 h hydrothermal reaction with sodium hydroxide. Depending on the reaction conditions, three types of synthetic zeolites were formed: Na-X (20 g fly ash, 0.5 dm³ of 3 mol · dm⁻³ NaOH, 75 °C), Na-P1 (20 g fly ash, 0.5 dm³ of 3 mol · dm⁻³ NaOH, 95 °C), and sodalite (20 g fly ash, 0.8 dm³ of 5 mol · dm⁻³ NaOH + 0.4 dm³ of 3 mol · dm⁻³ NaCl, 95 °C). As synthesized materials were characterized to obtain mineral composition (X-ray diffractometry, Scanning electron microscopy-energy dispersive spectrometry), adsorption properties (Brunauer-Emmett-Teller surface area, N₂ isotherm adsorption/desorption), and ion exchange capacity. The most effective reaction for zeolite preparation was when sodalite was formed and the quantitative content of zeolite from X-ray diffractometry was 90 wt%, compared with 70 wt% for the Na-X and 75 wt% for the Na-P1. Residues from each synthesis reaction were the following: mullite, quartz, and the remains of amorphous aluminosilicate glass. The best zeolitic material as characterized by highest specific surface area was Na-X at almost 166 m² · g⁻¹, while for the Na-P1 and sodalite it was 71 and 33 m² · g⁻¹, respectively. The ion exchange capacity decreased in the following order: Na-X at 1.8 meq · g⁻¹, Na-P1 at 0.72 meq · g⁻¹, and sodalite at 0.56 meq · g⁻¹. The resulting zeolites are competitive for commercially available materials and are used as ion exchangers in industrial wastewater and soil decontamination.

The mesoporous silicate molecular sieve, MCM-41, has been synthesized from pulverized coal fly ash (PFA), where the silicate filtrate used is a by-product from hydrothermal zeolite production. Rice husk ash was also used for comparison but fusion with sodium hydroxide was used to prepare the silicate filtrate, along similar lines to earlier reports of using PFA as a precursor for MCM-41 synthesis. The MCM-41 samples are chemically and mineralogically similar to a commercially available sample, but with higher pore volumes dominated by mesopores (0.92–1.13 cf. 0.88 cm3 g−1). After polyethyleneimine (PEI) impregnation for CO2 capture, the ash derived MCM-41 samples displayed higher uptakes than the commercial sample with the maximum achievable PEI loading of 60 Wt.% PEI (dry basis) before particle agglomeration occurs, approximately 13 compared to 11 Wt.%, respectively, the latter being comparable to earlier reports in the literature. The PFA sample that displays the fastest kinetics to achieve 90% of the equilibrium uptake had the largest mesopore volume of 1.13 cm3 g−1. Given the PFA-derived MCM-41 uses a waste silicate solution for hydrothermal preparation and no prior preparation is needed, production costs are estimated to be considerable lower where silicate solutions need to be prepared by base treatment, even if ash is used, as for the RHA derived MCM-41 used here

This paper presents a comprehensive study on the possibility of sewage sludge management in a sintered ceramic material such as a lightweight aggregate. Made from clay and sludge lightweight aggregates were sintered at two temperatures: 1100 °C (name of sample LWA1) and 1150 °C (name of sample LWA2). Physical and mechanical properties indicate that the resulting expanded clay aggregate containing sludge meets the basic requirements for lightweight aggregates. The presence of sludge supports the swelling of the raw material, thereby causing an increase in the porosity of aggregates. The LWA2 has a lower value of bulk particle density (0.414 g/cm³), apparent particle density (0.87 g/cm³), and dry particle density (2.59 g/cm³) than it is in the case of LWA1 where these parameters were as follows: bulk particle density 0.685 g/cm³, apparent particle density 1.05 g/cm³, and dry particle density 2.69 g/cm³. Water absorption and porosity of LWA1 (WA = 14.4 %, P = 60 %) are lower than the LWA2 (WA = 16.2 % and P = 66 %). This is due to the higher heating temperature of granules which make the waste gases, liberating them from the decomposition of organic sewage sludge. The compressive strength of LWA2 aggregate is 4.64 MPa and for LWA1 is 0.79 MPa. Results of leaching tests of heavy metals from examined aggregates have shown that insoluble metal compounds are placed in silicate and aluminosilicate structure of the starting materials (clays and sludges), whereas soluble substances formed crystalline skeleton of the aggregates. The thermal synthesis of lightweight aggregates from clay and sludge mixture is a waste-free method of their development.