Preparation of Binderless Silicoaluminophosphates by Vapor-Phase Crystallization of Kaolin–Phosphoric Acid Grains

Transformations of granules based on kaolin and phosphoric acid under conditions of vapor-phase crystallization in a mixture of water vapor and a structure-directing agent have been studied. It has been shown that silicoaluminophosphate granules obtained in the presence of dipropylamine, triethylamine, or tetramethylammonium hydroxide as a structure-directing agent consist of a shell formed by dense nonporous cristobalite, tridymite, and berlinite phases and the core made mainly of microporous crystalline silicoaluminophosphates. The formation of the shell, which ensures the strength of the silicoaluminophosphate granules, is due to the interaction of steam with the material of the granules at the initial stages of vapor-phase crystallization. It has been established that the selectivity of the structure-directing action of the amines under vapor-phase crystallization conditions basically corresponds to the template hydrothermal synthesis. It has been assumed that the specific features of the structure-directing action of dimethylamine during vapor-phase transport synthesis are due to its low boiling point, which ensures the primary contact of the granules with template, rather than water molecules. As a result, the products of the transformation of granules in the presence of a mixture of dimethylamine and water do not contain dense nonporous phases and are cocrystallized silicoaluminophosphate and calcium aluminosilicate with the gismondine structure.