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 dm 3 of water, the reaction temperature: 80°C and reaction time: 36 h), the highpurity (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 m 2 /g) c.a. six times higher than the fly ash from which it has been derived (15 m 2 /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.

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An initial study has been made of the use of synthetic zeolites for mercury capture from exhaust gases. Synthetic zeolites (Na-X and Na-P1), and for comparison a natural zeolite (clinoptilolite) and activated carbon with bromine (AC/Br) were tested for mercury uptake from a gaseous stream. The materials were subjected to mercury adsorption tests and their thermal stability was evaluated. The untreated synthetic zeolites had negligible mercury uptake, but after impregnation with silver, the adsorption of mercury was markedly improved.The synthetic zeolite Na-X impregnated with silver adsorbed significantly more mercury before breakthrough than the activated carbon impregnated with bromine, indicating the potential of zeolite derived from coal fly ash as a new sorbent for capture of mercury from flue gases.

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Zeolites are materials with known sorption properties. The sorption is thought to progress mainly by ion exchange with Na+, K+, Mg2+, Ca2+ or H+ from the zeolite exchange sites. The aim of the study was to compare the sorption properties of natural and synthetic zeolites on the example of the removal of selected metals from aqueous acidic solutions. Uptake experiments for selected ions of chromium, manganese, selenium, nickel, cobalt, and iron were performed using the batch and kinetic column methods. The sorption of the individual metal ions in mg per 1g of sorbent was determined for each sorbent. The relative affinity sequence of the examined cations toward the various sorbent was presented. The Langmuir model was used to model the adsorption equilibrium. Vermiculite under 1 mm of diameter (SF), Na-X, and Na-A were proved to be the most suitable for the individual uptake of studied metal ions. It was observed that the behavior of selenium ions differed from the remaining ones which was interpreted that selenium undergoes adsorption in the anionic form. The fixed-bed column studies were performed using Na-A, ensuring the sorption of selenium in the presence of iron(III) ions. The experiments were conducted using Na-X zeolite pre-loaded by Fe(III) as well as unmodified sorbent eluted by an equimolar mixture containing 100 ppm of Fe and Se. Obtained results prove that selenium sorption improves if other metal ions such as iron appear in the acidic solution. That efficient selenium sorption conditions can be applied to remove selenium which was recognized as toxic at higher levels.