The study assesses the feasibility of using Class C coal fly ash (CFA) to produce faujasite zeolite-X materials. This study primarily investigated the production and analysis of zeolites using coal fly ash (CFA) as a starting material. The authors have utilized the response surface methodology combined with central composite design approach to optimize the process variables. The examined operational parameters include fusion temperature, fusion time, liquid/solid (L/S) ratio, alkaline solution concentration and hydrothermal treatment time. The investigation revealed that samples were produced from three highly efficient reactions that took place under the following conditions: The NaOH/fly ash ratio for each of the three reactions was 1.5 and 1.75 respectively. The fusion temperature for all three reactions was 675°C, with a fusion time of 12-15 hours and a reaction time of 8 hours. The most superior zeolite materials were analyzed for their mineralogical properties using X-ray powder diffraction (XRD), scanning electron microscopy-energy-dispersive X-ray spectroscopy (SEM-EDS), BET surface analysis (for pore volume and pore width) and chemical composition using X-ray fluorescence (XRF). The findings obtained were comparable to the zeolite structures derived from coal fly ash. Thus, it can be inferred that the examined coal fly ash has the potential to serve as a suitable medium for the production of faujasite type zeolite materials. The XRF analysis validates the composition of the fly ash and the resulting Faujasite, consistent with prior findings and an enhanced composition. The surface area analyses (BET) revealed that the synthesized Faujasite has an active area of 1080 m2g−1 with pore volume of 0.662406 cm³/g and pore diameter 24.486 Å, whereas the fly ash only has an area of 60 m2g−1 for its physicochemical qualities. Meanwhile, the EDX analysis combined with SEM confirmed that the composition of the samples aligns with the desired outcomes and that the proposed methodology is supported by the observed morphological characteristics.