A new process route for obtaining zeolite 4A from kaolin was realized by subjecting all raw materials needed for hydrothermal synthesis to thermal activation in one pot method. For that purpose, different routes of activation steps for kaolin, which are metakaolinization, alkali fusion and one pot fusion were investigated for a wide range of kaolin sources in order to obtain zeolite 4A product with highest crystallinity. The influence of Si/Al ratio in addition to the chemical composition of raw kaolin, i.e. quartz and iron impurity content, on the product 4A was investigated following all three activation routes. It was found that alkali fusion process allows incorporation of quartz as silicon source during the hydrothermal synthesis of zeolite 4A, which may result in a variety of products such as zeolite P and zeolite 13X. In this study, a novel approach was developed by thermal activation of a mixture of kaolin, alkali and alumina sources at once in one pot route, which was followed by hydrothermal synthesis. The current study indicates the possibility of adjusting Si/Al ratio adding Al(OH)₃ during the activation step in one pot fusion process, which resulted in synthetic zeolite 4A of higher than 90% crystallinity using low quality kaolin.

通过以锅法对水热合成所需的所有原料进行热活化，实现了一种从高岭土获得沸石4A的新工艺路线。为此，研究了多种高岭土来源的高岭土活化步骤的不同途径，即间位高岭土化，碱熔和一锅熔合，以获得具有最高结晶度的沸石4A产物。按照所有三种活化途径，研究了硅/铝比以及生高岭土的化学组成（即石英和铁杂质含量）对产品4A的影响。已发现碱熔融过程允许在沸石4A的水热合成过程中掺入石英作为硅源，这可产生多种产物，例如沸石P和沸石13X。在这个研究中，通过在一个锅法中一次热活化高岭土，碱和氧化铝源的混合物，然后进行水热合成，开发了一种新方法。当前的研究表明添加Al（OH）可以调节Si / Al比在一锅熔合过程中的活化步骤₃中，使用低质量的高岭土导致合成沸石4A具有高于90％的结晶度。