Process for synthesizing and controlling the particle size and particle size distribution of a molecular sieve

摘要

Applicants have developed a continuous process for synthesizing various molecular sieves. The process enables one to control both the particle size and particle size distribution. Any of the molecular sieves represented by the empirical formula on an anhydrous basis: rR₂O:(Si_xAl_yP_z)O₂, where R is at least one structure directing agent, “r”, “x”, “y” and “z” are the mole fractions of R, Si, Al and P respectively, can be prepared using this process. The process involves continuously adding separate streams comprising reactive sources of at least each framework element into a continuous crystallization reactor. Either interstage backmixing is introduced or the number of stages is adjusted in order to control particle size.