A “waste” of time?: the synthesis of a magnesium-substituted aluminophosphate from an unconventional source of magnesium

Magnesium-substituted microporous aluminophosphates (MgAlPOs) are tuneable framework materials that exhibit strong Brønsted acidity and have found great utility as catalysts for a wide variety of green transformations. Typically, refined magnesium salts, such as magnesium acetate, are the source of magnesium used in the synthesis of MgAlPOs. However, magnesium is classified as a critical raw material, thus finding alternative sources of magnesium remains an important endeavour. Here we demonstrate the use of struvite, a mineral which can form as a problematic waste material, as a viable source of magnesium for the synthesis of MgAlPO-5 (AFI framework). Exploration of synthesis conditions showed that using struvite over magnesium acetate as the Mg source led to increased chabazite (CHA) contamination when triethylamine was employed as the template. The CHA phase impurity could be reduced through synthesis optimisation, though not eliminated when struvite was utilised. Phase pure AFI from struvite and magnesium acetate was formed when <i>N</i>,<i>N</i>-methyldicyclohexylamine was used as a template, and the gel stirred during crystallisation. Electron microscopy revealed that the struvite derived MgAlPO-5 materials exhibit a distinct surface morphology featuring nanorod-like growths, presumably associated with the magnesium source, although the underlying cause remains unclear. Despite this we show that both materials are acidic (DRIFTS and CD₃CN adsorption studies) and are active catalysts for the dehydration of ethanol to ethylene in the gas phase under flow conditions. In contrast, unsubstituted AlPO-5 shows limited acidity and negligible catalytic activity, validating the incorporation of magnesium into the framework from both magnesium sources. TEM-EDS maps also support this finding, showing a homogenous distribtution of Al, P and O (and Mg) for all materials synthesised. This work demonstrates that struvite can be used in MgAlPO synthesis, under optimised conditions, showing that repurposing this unconventional magnesium source is far from "a waste of time".