Application of kaolin-based synthesized zeolite membrane systems in water desalination

Abstract

Accessibility to potable water worldwide is threatene, despite 71% of the earth’s surface being covered with water. However, 97% of the 71% is too saline for consumption. A usual way of treating salinity is by membrane desalination using reverse osmosis. The disadvantage of this approach is its high cost and short life span of the polymeric membrane used. Creating a new robust high-quality water treatment system using a ceramic membrane will address these challenges due to its robust mechanical properties. In this work, we synthesized different zeolites from South African kaolin under varying conditions such as crystallization time, ageing time and temperature and their effects on the properties of zeolites synthesized was investigated. Sample characterization confirmed the successful synthesis of ZSM-5 and zeolite A. In the synthesis procedure, metakaolin served as the alternative source of silica and alumina and was use to synthesize different types of zeolites under varying synthesis conditions. Synthesized samples were characterized using X-ray diffraction (XRD), scanning electron microscopy (SEM), Fourier transform infrared (FTIR) spectroscopy and Brunauer–Emmett–Teller BET surface area. The properties of the synthesized ZSM-5 were influence by the synthesis parameters, typically, crystallization temperature, ageing time and crystallization time. Crystalline ZSM-5 zeolite produced at an ageing time of 24 hours, crystallization time of 48 hours and crystallization temperature of 180°C with Si/Al ratio of 43 and BET surface area of 282 m2 /g. After a 12-hour ageing period, Zeolite A produced at crystallization time of 20 hours, the crystallization temperature of 100°C, Si/Al ratio of 1.3 and BET surface area of 143.88 m2 /g. The findings indicate that aging influences the synthesis of zeolite A, as a relatively crystalline material formed at an ageing time of 12 hours, which continued to decrease as the ageing time was increased. We do not exclude the possibility of Ostwald ripening playing a role in this relationship. Subsequently, the efficiency of zeolite A and ZSM-5 zeolite in removing salt ions, Ca2+, K+ , Mg2+ , and Na+ from synthetic seawater was investigated at room temperature using a batch adsorption system. The effect of adsorbent dosage, agitation speed and contact time were consider. Dosages varied from 2.5 to 6.0 g/100 ml while the contact time varied from 30 to 180 minutes. The results obtained showed that a zeolite dosage of 6.0g/100 ml and agitation speed of 140 revolutions per minute (rpm) yielded a maximum removal efficiency of 89.7 % for Ca2+ and minimum removal efficiency of 1.8 % for Mg2+ at agitation rates of 30 and 120 minutes, respectively. Ion exchange of Na+ by Ca2+, K+ and Mg2+ in the zeolite framework was established. The preference of the overall ion-exchange selectivity of both zeolites A and ZSM-5 are in the order of Ca2+ > K+ > Na+ > Mg2+. Zeolite A showed higher removal efficiency compared to ZSM-5 zeolite. The results point out that the synthesized zeolite was able to desalinate the salt ions in synthetic seawater to a limit below the World Health Organization (WHO) recommended values. Consequently, zeolite synthesized from kaolin offers a cost-effective technology for the desalination of seawater. The desalination and material characterization results used in selecting a potential zeolite for use in reverse osmosis (RO). The material successfully deposited on etched alpha-alumina support to produce zeolite membrane by a hydrothermal technique using a modified in-situ method. Zeolite A and ZSM-5 membranes produced and applied in the RO unit for desalination. The RO membrane experimental results show potential in desalination of synthetic seawater. A machine-learning tool was use to predict the properties of the synthesized ZSM-5 as a function of the hydrothermal parameters. Finally, a techno-economic analysis of synthesizing zeolite using locally available kaolin at a capacity of 5 x 105 kg/yr. has shown that the plant is economically viable with rapid break-even and the payback period is less than 4 years.