Waste Aluminum Dust-Derived Functional Zeolites for Heavy Metal Removal and Water Softening: Synthesis, Purification, and Ion-Exchange Modification

Waste aluminum dust generated from aluminum refining and machining processes contains high fractions of Al2O3 and SiO2, making it a potential secondary aluminosilicate resource for zeolite synthesis. In this study, waste aluminum dust was converted into functional zeolite materials through dry fusion purification, NaOH-assisted hydrothermal synthesis, acid purification, Si/Al ratio control, and cation-exchange modification. The raw dust was subjected to dry fusion at 1600 °C under an Ar atmosphere to remove metallic impurities and obtain an aluminosilicate precursor. Na-type zeolite was then synthesized using 50 wt.% NaOH solution at 90 °C for 24 h. The as-synthesized Na-type zeolite exhibited an estimated chemical purity of 97.501 wt.% based on measured residual impurities, with Mg, Ca, K, and Ti remaining as major impurities. HCl leaching at 0.25 M for 24 h increased the estimated chemical purity based on measured residual impurities to 98.469 wt.% while retaining the major zeolitic diffraction features. The Si/Al ratio was further controlled using water glass, and the maximum Si/Al ratio of 1.77 was obtained at a Na-type zeolite-to-water-glass mass ratio of 1:2 after reaction at 90 °C for 6 h. The purified and composition-controlled zeolite was subsequently modified with Mg2+ and K+ ions to prepare Mg-modified and K-modified zeolites. Under fixed batch conditions using a relatively high zeolite dosage and a single initial concentration, Mg-modified zeolite reduced Pb, Hg, Cr(VI), and Cd concentrations from 100 ppm to 0.004, 0.00059, 0.018, and 0.004 ppm, respectively, while K-modified zeolite reduced the total hardness of synthetic hard water from 308.3 to 40.13 ppm as CaCO3. These results should be interpreted as preliminary batch-performance results under the tested conditions rather than as maximum adsorption capacities or a complete adsorption-mechanism evaluation. Overall, this study demonstrates the feasibility of valorizing waste aluminum dust into purified and cation-modified zeolite materials for potential water-treatment applications. Further adsorption isotherm, kinetic, dosage-dependent, BET surface area, pore-volume, pore-size distribution, and quantitative phase analyses are required to evaluate adsorption capacity, adsorption mechanism, true zeolite phase purity, and framework–performance relationships.