While commercial hydrodeoxygenation (HDO) processes convert fats, oils, and grease (FOG) to fuel-like hydrocarbons, alternative processes based on decarboxylation/decarbonylation (deCOx) continue to attract interest. In this contribution, the activity of 20% Ni-5% Cu/Al2O3 in the deCOx of waste free fatty acid (FFA)-based feeds—including brown grease (BG) and an FFA feed obtained by steam stripping a biodiesel feedstock—was investigated, along with the structure-activity relationships responsible for Ni promotion by Cu and the structural evolution of catalysts during use and regeneration. In eight-hour experiments, near quantitative conversion of the aforementioned feeds to diesel-like hydrocarbons was achieved. Moreover, yields of diesel-like hydrocarbons in excess of 80% were obtained at all reaction times during a BG upgrading experiment lasting 100 h, after which the catalyst was successfully regenerated in situ and found to display improved performance during a second 100 h cycle. Insights into this improved performance were obtained through characterization of the fresh and spent catalyst, which indicated that metal particle sintering, alloying of Ni with Cu, and particle enrichment with Cu occur during reaction and/or catalyst regeneration.

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