Synthesis of sub-micrometric SAPO-34 by a morpholine assisted two-step hydrothermal route and its excellent MTO catalytic performance

SAPO-34 with a sub-micrometer crystal size was synthesized by a double hydrothermal treatment employing cost-effective morpholine as a structure directing agent, which presented an enhanced catalytic lifetime (nearly 3 times the conventional one) in the reaction of methanol to olefins with a higher light olefin selectivity (total selectivity of 97.1%). Detailed studies of the sample after different time intervals in the second crystallization with and without additional morpholine were carried out, which offered insight into crystal degradation and re-crystallization phenomena. The samples with different morpholine concentrations during the second hydrothermal treatment were also prepared, in which the sample with 80% MOR aqueous solution exhibited the smallest crystal size and the longest MTO lifetime. Furthermore, the investigation on the additional amount of mother liquor (from the first crystallization) required for the second crystallization showed that the presence of half the amount of the mother liquor (nutrients) could give us the required results effectively.