Fly Ash-Derived Mesoporous Silica–Alumina Aerogel via an Optimized Water-Acid Leaching Process for Effective Methylene Blue Removal

Adsorption is a common method for solving the contamination of methylene blue (MB) in dyeing wastewater. Aerogel adsorbents with high porosity and specific surface areas have attracted increasing attention. However, the high costs of raw materials for aerogel preparation restrict their large-scale production and application. Fly ash (FA), a by-product of coal-fired power plants, is rich in silica and aluminum elements and has the potential to prepare aerogel adsorbents. This study proposed a modified recycling route for FA to synthesize silica–alumina composite aerogel with high specific surface area. FA was pretreated by three steps of alkali fusion, water leaching and acid leaching to obtain a solution rich in silicon and aluminum elements, with a total leaching efficiency of 96.92% and 91.36% for silicon and aluminum, respectively, under optimized alkaline fusion conditions of FA:NaOH mass ratio of 1:1.2, calcination time of 2 h, and calcination temperature of 550 °C. Silica–alumina aerogel with a specific surface area of 661.3 m2/g was then synthesized from the leaching solution through a sol–gel method, exhibiting well-developed mesopores and achieving an adsorption capacity of 52.22 mg/g for MB. The adsorption kinetics and isotherms of MB adsorption by FA-derived silica–alumina composite aerogel was investigated. FTIR characterization confirmed that the adsorption of MB by FA-derived aerogel was mainly physical adsorption. This study provides a new approach for the resource utilization of FA, and the high-specific-surface-area FA-derived aerogel holds potential as an alternative adsorbent for the removal of dyes in wastewater.