Synthesis, Characterization and Mechanical Evaluation of Zeolite-Y Derived from Ahoko Clay for Industrial Catalyst Applications

Abstract

The synthesis of zeolite catalysts from natural clay represents a sustainable pathway toward industrial materials that reduce reliance on imported raw resources. In this study, Zeolite‑Y was successfully synthesized and characterized from Ahoko clay, a kaolinitic deposit in Kogi State, Nigeria. The clay underwent beneficiation, acid leaching, and calcination at 500 °C to yield metakaolin, which was then subjected to hydrothermal crystallization under alkaline conditions. X‑ray diffraction confirmed the formation of the faujasite (FAU) framework typical of Zeolite‑Y, with distinct peaks at ~10°, ~12°, ~15°, and ~23° (2θ). Scanning electron microscopy revealed large, well‑intergrown octahedral crystals, consistent with FAU morphology. Thermogravimetric analysis demonstrated remarkable thermal stability up to 950 °C, while mechanical testing showed an unconfined compressive strength of 76.8 kN/m². Together, these findings highlight Ahoko clay as a promising local precursor for producing industrial‑grade Zeolite‑Y. Beyond its technical merits, this work underscores the broader significance of harnessing indigenous resources to advance sustainable catalyst manufacturing, reduce dependency on foreign imports, and add value to Nigeria’s abundant clay reserves. By integrating structural, mechanical, and thermal insights, the study offers a more holistic view of catalyst durability and its role in sustainable industrial development.