One-Step Synthesis of the P-ZSM-5 Zeolite from Yellow Phosphorus Slag and Its Potential Application for Methanol to Propylene

Low-valuable utilization and a massive accumulation of yellow phosphorus slag (YPS) have caused severe pollution in surrounding environments. Among numerous implementation strategies, the conversion of YPS into phosphorus-containing zeolites represents a promising approach for high value-added utilization. Herein, we report that P-ZSM-5 zeolites were successfully prepared from acid-leaching YPS in one step using a hydrothermal synthesis method. The obtained P-ZSM-5 zeolites exhibited high crystallinity, uniform crystal size (200–400 nm), and a large BET surface area (>400 m2/g). Accordingly, a nonclassical crystallization mechanism of P-ZSM-5 zeolites from the YPS was proposed by multiple advanced characterizations. Importantly, the presence of phosphorus not only induced framework Al sited in the straight/sinusoidal channels and improved the hydrothermal stability of the zeolite framework but also enhanced the Brønsted acidity. Under comparable conditions, the as-prepared P-ZSM-5(75) zeolite catalyst with a higher ratio of Brønsted/Lewis acid sites in the methanol-to-propylene reaction exhibited a considerable catalytic lifetime (30 h, WHSV = 6 h–1), high propylene selectivity (55.1%), and a propylene-to-ethylene ratio of 5.9. The advancement in P-ZSM-5 zeolites paves a novel way for more effective YPS utilization and driving sustainability in phosphorus-based chemical production.