Shaping and optimal compositional formulation are major challenges in the successful industrial application of heterogeneous catalysts. The choice of components during formulation plays a vital role in endowing the final catalyst's mechanical strength, durability, and lifetime and may even affect activity and selectivity. Herein, we evaluate the application of spray drying to manufacture spherical ZSM-5-based catalysts and their applicability in the methanol-to-olefins process. Several critical parameters of the spray drying process and various aspects related to catalyst formulation (binder, zeolite, and clay) are investigated. Chemical composition and structure of the clay matrix substantially influence the catalytic performance.
Keywords: catalyst shaping; composite catalyst; methanol-to-olefins (MTO); spray drying; zeolite.