One-Pot Synthesis of Sustainable Aviation Fuel from Brown Grease Using Multifunctional Zeolite-Supported Catalysts

The most viable way to decarbonize aviation in the near term is through Sustainable Aviation Fuel (SAF), most of which is currently produced via the deoxygenation of fats, oils, and greases (FOG) followed by a separate isomerization step. Multifunctional zeolite-supported catalysts offer several advantages over existing formulations, such as enabling the use of waste FOG streams, performing their deoxygenation via decarboxylation/decarbonylation (deCOx), and effecting the synthesis of SAF in one-pot. Previous work has shown that while supported Ni-Cu catalysts can afford excellent results in the conversion of waste FOG to fuel-like hydrocarbons via deCOx, zeolitic materials represent promising supports in formulations employed for the synthesis of SAF. In this contribution, catalysts involving different zeolitic supports and the same Ni-Cu active phase were prepared, characterized, and tested in the conversion of brown grease to SAF to identify the carrier affording the best results. A Ni-Cu/ZSM-5 catalyst displayed the highest conversion and yield of SAF-like hydrocarbons relative to formulations supported on ZSM-22, SAPO-11, or SAPO-34 (these catalysts being referred to herein as NCZSM-5, NCZSM-22, NCSAPO-11, and NCSAPO-34).