Synthesis of monolithic Al-fiber@HZSM-5 core-shell catalysts for methanol-to-propylene reaction

•We developed a microfibrous-structured Al-fiber@HZSM-5 core-shell catalyst.•Core-shell catalyst is obtained by growth of HZSM-5 on sinter-locked Al fibers.•Such catalyst offers selectivity and lifetime improvement in MTP reaction.•This approach provides a good combination of high thermal conductivity and hierarchical 3D porous structure.

Monolithic microstructured Al-fiber@HZSM-5 core-shell catalysts have been synthesized by directly growing the shell of HZSM-5 with varied SiO2/Al2O3 molar ratio on the core of sinter-locked aluminum microfibers. Such monolithic catalysts are examined in the methanol-to-propylene reaction, and the best microstructured catalyst of HZSM-5 with SiO2/Al2O3 molar ratio of 200 delivers a C2–C4 selectivity of 62% (~ 36% to C3) as well as a single-run lifetime of 160 h under industrial relevant conditions.

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