Ex-situ catalytic pyrolysis of lignocellulosic biomass is an intriguing technology that combines thermal deconstruction of the feedstock with upgrading of the vapour and liquid intermediates. To date, in contrast with the current fossil fuel-based industrial processes, several fundamental challenges still impede its widespread deployment to generate renewable, cost-competitive biofuels and/or value-added chemicals. Catalyst improvements and process development offer a substantial opportunity to advance the technology. In this work, a novel zeolite catalyst SiC@MZSM-5 was successfully synthesized by growing ZSM-5 on SiC nanowires. The improved thermal conductivity was envisioned to minimize adverse effects of the downstream fixed-bed temperature fluctuation resulting from strong exothermic reactions during catalytic upgrading, hence fostering product distribution regulation. Concurrently, the pyrolysis process was managed to remove the heavy fractions from pyrolysis vapours by its internal recycling and forced secondary degradation, alleviating catalyst deactivation risk and thus extending the regeneration interval. The co-optimization of catalyst and process strategy improved the catalyst lifetime, optimized fixed-bed temperature distribution, and preserved the catalytic performance. (C) 2020 Published by Elsevier Ltd.