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The increase of global environmental restrictions concerning solid and liquid industrial waste, in addition to the problem of climate change, which leads to a shortage of clean water resources, has raised interest in developing alternative and eco-friendly technologies for recycling and reducing the amount of these wastes. This study aims to utilize Sulfuric acid solid residue (SASR), which is produced as a useless waste in the multi-processing of Egyptian boiler ash. A modified mixture of SASR and kaolin was used as the basic component for synthesizing cost-effective zeolite using the alkaline fusion-hydrothermal method for the removal of heavy metal ions from industrial wastewater. The factors affecting the synthesis of zeolite, including the fusion temperature and SASR: kaolin mixing ratios, were investigated. The synthesized zeolite was characterized by X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), scanning electron microscopy (SEM), particle size analysis (PSD) and N2 adsorption-desorption. The SASR: kaolin weight ratio of 1:1.5 yields faujasite and sodalite zeolite with 85.21% crystallinity, which then shows the best composition and characteristics of the synthesized zeolite. The factors affecting the adsorption of Zn2+, Pb2+, Cu2+, and Cd2+ ions from wastewater on synthesized zeolite surfaces, including the effect of pH, adsorbent dosage, contact time, initial concentration, and temperature, have been investigated. The obtained results indicate that a pseudo-second-order kinetic model and Langmuir isotherm model describe the adsorption process. The maximum adsorption capacities of Zn2+, Pb2+, Cu2+, and Cd2+ ions onto zeolite at 20 °C were 12.025, 15.96, 12.247, and 16.17 mg·g−1, respectively. The main mechanisms controlling the removal of these metal ions from aqueous solution by synthesized zeolite were proposed to be either surface adsorption, precipitation, or ion exchange. The quality of the wastewater sample obtained from the Egyptian General Petroleum Corporation (Eastern Desert, Egypt) was highly improved using the synthesized zeolite and the content of heavy metal ions was significantly reduced, which enhances the utilization of the treated water in agriculture.