Conversion of exhausted fluid cracking catalysts into zeolites by alkaline fusion

Na2CO3 fusion was used to improve the conversion of exhausted fluid cracking catalysts into NaA zeolite. Experiments were performed varying the catalyst/Na2CO3 mass ratios and the heating treatment. X-ray diffraction analysis was used to identify the different crystalline phases present in the starting material as well as in the products. Quantitative determination of crystalline phases was performed by Rietveld analysis. Particle sizes and morphology were observed by electronic scanning microscopy. The proposed activation methodology led to high crystallization rates and good conversion in NaA zeolite.