A versatile electrospinning method to fabricate ZSM-5-decorated MgO nanofibers as a catalyst for methanol to light olefins: Toward remarkable stability and superior performance

Abstract

In response to the increasing concerns about climate change and the depletion of fossil fuel reserves, the application of zeolite ZSM-5 as a catalyst in the methanol to olefin (MTO) process is considered a promising chemical technique. It holds the potential to produce essential chemical building blocks, such as light olefins, using sustainable raw materials. In this study, electrospun MgO/ZSM-5 nanofibers were synthesized to enhance mass/heat transfer limits during the MTO process and improve catalyst stability. In this synthesis, ZSM-5 nanoparticles with a mean diameter of 600 nm were arranged on magnesium oxide nanofibers with a mean diameter of 200 nm. The catalysts were characterized using various techniques, including XRD, SEM, TEM, EDX-Mapping, NH3-TPD, BET, and TGA. The electrospinning technique prevented nanoparticle accumulation and improved the morphology of the catalyst. In an isothermal fixed-bed reactor, the catalysts were tested at 450 °C, 1 atm, WHSV = 4.5 hr−1, with a methanol-water solution in a 1:1 (v/v) ratio as the feed. The stability of the nanofibers was found to be enhanced compared to ZSM-5 nanoparticles. MgO/ZSM-5-50 nanofibers (50 wt% zeolite), MgO/ZSM-5-80 nanofibers (80 wt% zeolite), and ZSM-5 nanoparticles exhibited methanol conversion rates of 99 %, 88 %, and 76 %, respectively, after 430 min of continuous operation. Furthermore, the amount of coke formed after 10 h for MgO/ZSM-5-50, MgO/ZSM-5-80, and ZSM-5 was 11.83 wt%, 13.63 wt%, and 20.98 wt%, respectively. The reduced coke formation on the electrospun samples compared to ZSM-5 nanoparticles demonstrates improved performance and stability for nanofiber catalysts.