Eco-Friendly Conversion of Waste Zeolite Dust into Dual Oil/Water Affinity Sorbents via HPGR-Based Agglomeration–Deagglomeration

This study presents an innovative, eco-friendly approach for converting waste zeolite dust into efficient petroleum sorbents through an integrated agglomeration–deagglomeration process using high-pressure grinding rolls (HPGRs). This method generates secondary porosity without calcination, enhancing sorption while reducing greenhouse gas emissions and supporting sustainable development by valorizing industrial by-products for environmental remediation. The study aimed to assess the influence of binder and water content on petroleum sorption performance, textural properties, and mechanical strength of the produced sorbents, and to identify correlations between these parameters. Sorbents were characterized using mercury porosimetry (MIP), sorption measurements, mechanical resistance tests, scanning electron microscopy (SEM), and digital microscopy. Produced zeolite sorbents (0.5–1 mm) exceeded the 50 wt.% sorption threshold required for oil spill cleanup in Poland, outperforming diatomite sorbents by 15–50% for diesel and 40% for used engine oil. The most effective sample, 3/w/22.5, reached capacities of 0.4 g/g for petrol, 0.8 g/g for diesel, and 0.3 g/g for used oil. The sorption mechanism was governed by physical processes, mainly diffusion of nonpolar molecules into meso- and macropores via van der Waals forces. Sorbents with dominant pores (~4.8 µm) showed ~15% higher efficiency than those with smaller pores (~0.035 µm). The sorbents demonstrated amphiphilic behavior, enabling simultaneous uptake of polar (water) and nonpolar (petrochemical) substances.