Studies on the synthesis of SAPO-5

Silicoaluminophosphate (SAPO-5) molecular sieves have been synthesised from reaction mixtures having a molar composition of: 0.7–1.0 Al₂O₃:0.7–1.0 P₂O₅:0.01–2.0 SiO₂:xR:40 H₂O (where R = (C₂H₃)₃N or (C₂H₃)₄NOH and x = 1.5–2.5 for (C₂H₅)⁵N and 0.5 for (C₂H₅)₄NOH, at 473 K using various sources of alumina and silica. The effects of (i) varying the crystallinity of the alumina source (boehmite) and (ii) the use of different silica sources such as freshly prepared silica either from sodium silicate or paddy husk extract, silica gel from commercial water-glass, and tetraethyl orthosilicate have been studied. The crystallinity of boehmite has been found to have a strong effect on its reactivity towards the formation of SAPO-5. The activity of boehmite for SAPO-5 formation increased with a decrease in its crystallinity (or with increase in its moisture content). Any silica source devoid of sodium ions could be employed for the synthesis of SAPO-5. The process of crystallisation started as early as within 1.5 h of reaction and incorporation of silicon into the AlPO₄ framework has been noted at this stage. Formation of some tridymite phase as impurity has been observed under conditions such as (i) SiO₂ concentration > 1.7 mole and (ii) x > 2.0 when R = (C²H₅)₃N.