Coal Fly Ash (CFA) was converted to zeolite using continuous microwave reactors while minimizing the wastewater produced during the zeolitization process. At bench scale, a continuous flow tubular microwave reactor was used to explore the effect of microwave irradiation on the crystallinity of the product. The waste water was reused in consecutive runs and Inductively Coupled Plasma (ICP) analysis was conducted during and after each run to observe the concentration of the cations. An increase

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... the production of hydroxysodalite compared to zeolite-A was noted at higher levels of microwave energy. The XRD and SEM analyses were also conducted to corroborate the results. The Cation Exchange Capacity (CEC) measurement showed the highest value of 0.405 meq/g when Deionized (DI) water was used, the CEC dropped to 0.177 meq/g for thrice recycled waste stream. It was also found that higher microwave irradiation resulted in faster crystal growth and the product crystallinity reached its maximum at 810 W of microwave irradiation in 60 min while 335 W of microwave irradiation resulted in the same crystallinity after 120 min of reaction.