Binder-free zeolite NaX foams were successfully prepared through a novel one-step geopolymer-gels-conversion approach using H2O2 solution as a foaming agent. Unlike traditional methods that utilize clay materials combined with expensive chemical Si
Al reagents as precursors, metakaolin and natural clinoptilolite (mass ratio = 1:1) were selected as Si
Al sources for zeolite NaX synthesis. Zeolite foams were systematically characterized and their CO2 adsorption performance was evaluated. Crystalline phases in natural clinoptilolite (clinoptilolite, albite, illite and quartz) and impurity phases in metakaolin (anatase and quartz) were found to be partially or completely dissolved during alkaline activation process. The resultant foam products exhibit hierarchical porosity, featuring macropores (∼1–2 mm) and zeolite micropores, with compressive strength of 0.83–2.6 MPa, bulk density of 0.51–0.84 g/cm3, BET surface area of 33.18–188.79 m2/g and CO2 adsorption capacity of 0.24–1.84 mmol/g (1 bar). Pure phase binder-free zeolite NaX foam with the relatively high crystallinity, suitable compressive strength (1.48 MPa), and high BET surface area (188.79 m2/g) was synthesized at SiO2/Al2O3 molar ratio = 3.4, SiO2/Na2O molar ratio = 3.8, NaOH activator concentration = 10 M, crystallization temperature of 80 °C and crystallization time of 24 h. This work presents an innovative perspective on developing clay materials as promising Si
Al sources for zeolite synthesis.
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