ZSM‐5 zeolite was synthesized using n‐butylamine as a template under hydrothermal conditions. The morphology of the prepared zeolites was changed with the initial gel composition. The influences of OH−/template and H2O/template ratios on the morphology, mesoporosity, acid properties, and crystal size of the synthesized zeolites were evaluated, also the structural effects of the prepared zeolites on the catalytic performances of the methanol‐to‐propylene process. Increasing the external surface area and mesopore volume of the catalysts improved the propylene selectivity. A direct relationship between the deactivation of catalysts and their acidic properties was found. The results were derived from laboratory data and need to be re‐examined on a larger scale to ensure their accuracy on an industrial scale.