• • Hier-ZSM-5-S achieved an average ethylene and propene selectivity of 63.5% over 22.2 hours on stream (WHSV = 3.6 h−1, T = 480°C), a 19% improvement and 6.5-fold longer lifetime compared to Micro-ZSM-5, directly addressing industrial MTO durability and selectivity bottlenecks.
• • The engineered hierarchical ZSM-5 sheet exhibits a b-axis thickness below 50 nm, quantitatively confirmed by 3D electron tomography, which shortens diffusion path lengths and enhances molecular transport, a critical factor for catalytic efficiency.
• • Coke accommodation was increased to 16.31 wt% with a deposition rate of 0.59 mg g−1 h−1, only one-third of that observed in Micro-ZSM-5, indicating superior resistance to deactivation and potential for extended operational cycles.
• • Real-time confocal laser scanning microscopy (CLSM) tracking provided direct evidence of enhanced molecular diffusivity in Hier-ZSM-5-S compared to conventional micron-sized ZSM-5, validating the design principle of hierarchical porosity for improved mass transfer.