Synthesis of sodium silicate using industrial by-products glauber’s salt and microsilica: Effective reuse of the waste

Large amounts of by-products, including glauber’s salt (GS) and microsilica (MS), are accumulated from chlor-alkali industry and ferrosilicon industry development, which not only wastes precious resources, but also causes serious environmental problems. In order to recycle and reuse these industrial by-products, solid sodium silicate was synthesized using GS and MS as the main raw materials, and semi-coke (SC) as the reducing agent. The effects of melting parameters including GS/SC and MS/GS molar ratio, heating rate, temperature, reaction time, and SC particle size on the conversion efficiency and modulus of solid sodium silicate were investigated and optimized. Under optimal conditions, the maximum conversion efficiency of 94.91% was obtained with modulus of 2.5. Characterization analysis of the products indicated that the amorphous silicate sodium was successfully synthesized. Moreover, the reaction mechanism was investigated, which focused on the thermal behavior and phase transformation using thermo-gravimetric and differential scanning calorimetric (TG-DSC) and in-situ X-ray diffraction. Additionally, the causes and suppression measures of “glauber’s salt water” (GSW) during the experiment were summarized. This work not only creates resource utilization of GS and MS, but also provides the foundation for the synthesis of sodium silicate with GS.