High-performance thin-felt SS-fiber@HZSM-5 catalysts synthesized via seed-assisted vapor phase transport for methanol-to-propylene reaction: Effects of crystal size, mesoporosity and aluminum uniformity

A series of thin-felt SS-fiber@HZSM-5 catalysts are fabricated via the seed-assisted vapor-phase transport (VPT) method. The crystal size and mesoporosity of zeolite shell are controllably tuned toward enhanced diffusion by increasing the silicalite-1 seeding gel (SG) amount used. The microstructured catalyst obtained with a high SG amount of 50% contains a smaller crystal size of ∼70 nm and higher mesopore volume of 0.21 cm³ g_zeolite⁻¹, which markedly prolonged single-run lifetime with a remarkable decrease in the coking rate in the MTP process. The adverse effect of non-uniform aluminum in the zeolite shell on the MTP stability is revealed. The use of aluminum-containing SG to replace the pure-silica one makes the acid sites of as-obtained ZSM-5 mounted on SS-fiber distributed homogeneously thereby leading to a marked suppression of hydrogen transfer, and as a result, the catalyst single-run lifetime is further increased by ∼40%. This promising SS-fiber@HZSM-5 catalyst is stable for at least 1600 h (>94% conv.) with a high propylene selectivity of ∼36% at 450 °C using a WHSV of 1 h⁻¹ for a feed of MeOH/H₂O molar ratio of 1:1, by taking advantage of improved diffusion from mesoporosity development and uniform aluminum distribution as well as our distinctive microfibrous-engineered design.