Synthesis of SAPO-56 with controlled crystal size

Abstract

Herein, we present the hydrothermal synthesis of SAPO-56 crystals with relatively controlled crystal/particle size. The effects of water content, aluminum source, gel composition, stirring, crystallization temperature and time, as well as the incorporation of crystal growth inhibitors during synthesis were systematically investigated. The synthesized SAPO-56 crystals displayed BET surface areas as high as ∼630 m2 g−1 with relative narrow size distribution in the ∼5–60 μm range. Nitrogen BET surface areas in the 451 to 631 m2 g−1 range were observed. Decreasing the crystallization temperature from 220 to 210 °C helped to decrease the average SAPO-56 crystal size. Diluted gel compositions promoted the formation of smaller crystals. Crystal growth inhibitors were found to be helpful in reducing crystal size and narrow the size distribution. Specifically, ∼5 μm SAPO-56 crystals displaying narrow size distribution were synthesized employing aluminum-tri-sec-butoxide as Al source, high water content, and high stirring rates.