Industrial ZSM-5 catalysts suffer from coke deposition and loss of activity in methanol to propylene conversion. Developing zeolites with a better diffusion path, which is essential for the design of high-efficiency catalysts, is still a challenge to be achieved. The synthesis of seed-induced ZSM-5 zeolite with a short diffusion path could be a solution to reduce coke accommodation and have a higher catalytic lifetime. However, it would not be beneficial with current methods as far as the industrial aspect. Herein, we have proposed a successful and industrially-feasible approach for decreasing the costs of seed-induced ZSM-5 synthesis as well as improving the lifetime and catalytic performance of ZSM-5 zeolites in the methanol to propylene (MTP) reaction. This modified seeding route includes a physical factor (ball milling) and a chemical factor (alkaline treatment). Compared to a conventional seed-induced route, this new technique allowed us to increase catalyst lifetime (from 159 h to 265 h), propylene/ethylene selectivity (from 5.23 to 8.19), and amount of produced propylene per gram of catalyst (from 182 gC3H6/gcat to 443 gC3H6/gcat). This modified seed has a high potential for use on an industrial scale, based on the results.
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