Biotemplating of Luffa cylindrica sponges to self-supporting hierarchical zeolite macrostructures for bio-inspired structured catalytic reactors

Biomorphic self-supporting MFI-type zeolite frameworks with hierarchical porosity and complex architecture were prepared using a 2-step (in-situ seeding and secondary crystal growth) hydrothermal synthesis in the presence of a biological template (Luffa sponge), employed as a macroscale sacrificial structure builder. The bio-inspired zeolitic replica inherited the complex spongy morphology and the intricate open-porous architecture of the biotemplate. Moreover, it exhibited reasonable mechanical stability in order to study the applicability of the biomorphic catalyst in a technical catalytic process. A bio-inspired catalytic reactor utilising the self-supporting ZSM-5 scaffold in monolithic configuration was developed in order to test the catalytic performance of the material.