Synthesis of carbon molecular sieves from palm shell by carbon vapor deposition

A series of experiments were conducted to produce carbon molecular sieves (CMS) through carbon deposition from a locally available palm shell of Tenera type for separating gaseous mixtures. The process involves three stages; carbonization, physical activation with steam, and carbon deposition by using benzene cracking technique. Carbonization of the dried palm shells was occurred at 900°C for duration of 1 h followed by steam activation at 830°C for 30–420 min to obtain activated carbons with different degree of burn-offs. The highest micropore volume of activated carbon obtained at 53.2% burn-off was used as a precursor for CMS production. Subsequent carbon deposition of the activated sample at temperature range from 600 to 900°C for 30 min has resulted in a series of CMSs with different selectivities of CO₂/CH₄ and O₂/N₂. The kinetic adsorption isotherm of CO₂, CH₄, O₂ and N₂ at room temperature also presented in this work.     

Carbonization and CO<Subscript>2</Subscript> activation of scrap tires: Optimization of specific surface area by the Taguchi method

This research demonstrates the production of activated carbon from scrap tires via physical activation with carbon dioxide. A newly constructed apparatus was utilized for uninterrupted carbonization and activation processes. Taguchi experimental design (L16) was applied to conduct the experiments at different levels by altering six operating parameters. Carbonization temperature (550–700 °C), activation temperature (800–950 °C), process duration (30–120 min), CO₂ flow rate (400 and 600 cc/min) and heating rate (5 and 10 °C/min) were the variables examined in this study. The effect of parameters on the specific surface area (SSA) of activated carbon was studied, and the influential parameters were identified employing analysis of variance (ANOVA). The optimum conditions for maximum SSA were: carbonization temperature=650 °C, carbonization time=60 min, heating rate=5 °C/min, activation temperature= 900 °C, activation time=60 min and CO₂ flow rate=400 cc/min. The most effective parameter was activation temperature with an estimated impact of 49%. The activated carbon produced under optimum conditions was characterized by pore and surface structure analysis, iodine adsorption test, ash content, scanning electron microscopy (SEM) and Fourier transform infrared spectroscopy (FTIR). The process yield for optimized activated carbon was 13.2% with the following properties: specific surface area=437 m²/g, total pore volume=0.353 cc/g, iodine number=404.7 mg/g and ash content=13.9% along with an amorphous structure and a lot of oxygen functional groups. These properties are comparable to those of commercial activated carbons.     

Preparation of ultra-thin PAN-based activated carbon fibers with physical activation

This study elucidates the stabilization and activation in forming activated carbon fibers (ACFs) from ultra-thin polyacrylonitrile (PAN) fibers. The effect of stabilization time on the properties and structure of resultant stabilized fibers was investigated by thermal analysis, X-ray diffraction (XRD), elemental analysis, and scanning electron microscopy (SEM). Stabilization was optimized by the pyrolysis of ultra-thin PAN fibers in air atmosphere at 280°C for 15 min, and subsequent activation in steam at 1000°C for 0.75 to 15 min. Resultant ACFs were characterized by N₂ adsorption at 77 K to evaluate pore parameters, XRD to evaluate structure parameters, and field emission scanning electron microscopy (FESEM) to elucidate surface morphology. The produced ACFs had surface areas of 668–1408 m²/g and a micropore volume to total pore volume ratio from 78 to 88%. Experimental results demonstrate the surface area and micropore volume of 1408 m²/g and 0.687 cm³/g, respectively, following activation at 1000°C for 10 min. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Preparation and Phosphine Adsorption of Activated Carbon Prepared from Walnut Shells by KOH Chemical Activation

Walnut-shell activated carbons (WSACs) with high surface area and predominant micropore development were prepared by KOH chemical activation. The effects of carbonization temperature, activation temperature, and ratio of KOH to chars on the pore development of WSACs and PH₃ adsorption performance of the modified walnut-shell activated carbons (MWSACs) were studied. Criteria for determining the optimum preparation conditions were pore development of WSACs and PH₃ breakthrough adsorption capacity of MWSAC adsorbents. The result shows that the optimum preparation conditions are a carbonization temperature of 700°C, an activation temperature of 700°C, and a mass ratio of 3. The BET surface area and the micropore volume of the optimal WASC are 1636m²/g and 0.641cm³/g, respectively. The micropore volume percentage of WSAC plays an important role in PH₃ adsorption when there is a slight difference in BET surface areas. High-surface-area WSACs with predominant micropores are suitable for PH₃ adsorption removal. The MWSAC adsorbent owns the biggest PH₃ breakthrough adsorption capacity (284.12mg/g) due to the biggest specific surface area, total pore volume, and micropore volume percentage. The MWSAC adsorbent will be a potential adsorbent for PH₃ adsorption removal from yellow phosphorus tail gas.     

Preparation and characterization of activated carbons for SO<Subscript>2</Subscript> adsorption from Taixi anthracite by physical activation with steam

Taixi anthracite was used as a precursor to prepare activated carbons (AC) for SO₂ adsorption from flue gas. In this work the activated carbons were prepared by physical activation with steam. Specifically, the effects of activation temperature and burn-off degree on the physico-chemical properties of the resulting AC samples were comparatively studied. The different types of pore volumes, pore size distributions and surface chemistries of the activated carbons on the SO₂ adsorption were also analyzed. The results show that the increasing burn-off leads to samples with continuous evolution of all types of pores except ultramicropore. The ultramicropore volume increases to a maximum of 0.169 cm³/g at around 50% burn-off and then decreases for 850 °C activation. At higher activation temperature, the micropore volume decreases and the mesopore structure develops to a certain extent. For all the resulting AC samples, the quantities of the basic surface sites always appear much higher than the amount of the acidic sites. The activated carbon prepared with higher micropore volume, smaller median pore diameter and higher quantities of the basic surface sites represents better SO₂ sorption property.     

Preparation and Characterization of Activated Carbon from Eucalyptus Sawdust I. Activated by NaOH

Eucalyptus sawdust was used as a precursor to prepare activated carbon using NaOH as a chemical activation agent. The effect of preparation conditions on the characteristics of the produced activated carbon used as an adsorbent was investigated. The performance of the activated carbon was characterized by N₂ adsorption–desorption isotherms, Brunauer–Emmett–Teller equation, Barett–Joyner–Halenda equation, scanning electron microscopy and Fourier transform infrared analysis. When the eucalyptus sawdust mass was 30.00 g, with particle sizes between 0.25 and 0.42 mm, and the sawdust was heated and charred before activation by NaOH, the optimized conditions for the preparation of activated carbon was found to be as follows: mass ratio of NaOH to eucalyptus sawdust, 1:2; activation time, 30 min; and activation temperature, 700 °C. The Iodine number and BET surface area of the produced activated carbon was 899 and 1.12 × 10³ m² g^?1, respectively, with a 13.3 % yield. Activated carbon exhibits adsorption isotherms of type IV. The total pore volume, micropore volume and average pore diameter were recorded as 0.636, 0.160 cm³ g^?1 and 2.27 nm, respectively. The pore structure of the activated carbon is mainly mesoporous. Carbonyl and hydroxyl groups may also exist on the activated carbon surface.     

Preparation and characterization of chars and activated carbons from Saskatchewan lignite

Saskatchewan lignite was used as a precursor to prepare carbonaceous adsorbents for use as SO₂ adsorbent from flue gases. The lignite was carbonized producing char in a fixed bed microreactor system at different temperatures from 350 to 550 ^°C in nitrogen atmosphere. The chars obtained at 475 ^°C for 120 min exhibited the highest micropore surface area (136 m²/g) and volume (0.062 cm³/g) and the smallest median pore diameter (∼ 0.7 nm). Carbon dioxide and steam were used as activating agents. Activation of char at optimum conditions of 650–675 ^°C for 15 min with carbon dioxide and steam resulted in a further increase in micropore surface area (220 and 186 m²/g for CO₂ and steam, respectively) and volume (0.090 and 0.085 cm³/g for CO₂ and steam, respectively). The yield of char was 64 wt.%, while the yields of activated carbon were 60 and 57 wt.% for CO₂ and steam activation, respectively; all based on the mass of original lignite.     

Comparative study of the textural characteristics of oil palm shell activated carbon produced by chemical and physical activation for methane adsorption

The objective of this study is to relate textural and surface characteristics of microporous activated carbon to their methane adsorption capacity. Oil palm shell was used as a raw material for the preparation of pore size controlled activated carbon adsorbents. The chemical treatment was followed by further physical activation with CO₂. Samples were treated with CO₂ flow at 850 °C by varying activation time to achieve different burn-off activated carbon. H₃PO₄ chemically activated samples under CO₂ blanket showed higher activation rates, surface area and micropore volume compared to other activation methods, though this sample did not present high methane adsorption. Moreover, it was shown that using small proportion of ZnCl₂ and H₃PO₄ creates an initial narrow microporosity. Further physical activation grantees better development of pore structure. In terms of pore size distribution the combined preparation method resulted in a better and more homogenous pore size distribution than the conventional physical activation method. Controlling the pore size of activated carbon by this combined activation technique can be utilized for tuning the pore size distribution. It was concluded that the high surface area and micropore volume of activated carbons do not unequivocally determine methane capacities.     

Synthetic carbons activated with phosphoric acid: II. Porous structure

Synthetic activated carbons were prepared by H₃PO₄ activation of a chloromethylated and sulfonated copolymer of styrene and divinylbenzene, using an impregnation weight ratio of 0.75 and carbonization temperatures in the 400-1000 °C range. Other impregnation ratios (0.93 and 1.11) were also used at a carbonization temperature of 800 °C. The porous texture of the resulting carbons was characterized by N₂ adsorption at −196 °C and CO₂ adsorption at 0 °C. All carbons exhibited a multimodal pore size distribution with maxima in the micropore and meso/macropore regions. Maxima in pore volume were attained at 900 °C for micropores and at 500 and 900 °C for mesopores. The mesopore volume was less sensitive than the micropore volume to changes in the impregnation ratio. It is concluded that the porous texture is not a prime factor in determining the outstanding cation exchange capacities of these carbons.     

Synthesizing activated carbons from resins by chemical activation with K2CO3

We prepared activated carbons from phenol-formaldehyde (PF) and urea-formaldehyde (UF) resins by chemical activation with K₂CO₃ with impregnation during the synthesis of the resins. The influence of carbonization temperature (773-1173 K) on the pore structure (specific surface area and pore volume) and the temperature range at which K₂CO₃ worked effectively as an activation reagent, were investigated. The specific surface area and micropore volume of PF-AC and UF-AC increased with an increase of carbonization temperature in the range of 773-1173 K. We prepared activated carbon with well-developed micropores from PF, and activated carbon with high specific surface area (>3000 m²/g) and large meso-pore volume from UF. We deduced the activation mechanism with thermogravimetry and X-ray diffraction. In preparing activated carbon from PF, K₂CO₃ was reduced by carbon in the PF char. The carbon was removed as CO gas resulting in increased specific surface area and pore volume above 1000 K. In preparing AC from UF, above 900 K the carbon in UF char was consumed during the K₂CO₃ reduction step.     

Influence of pretreatment and activation conditions in the preparation of activated carbons from anthracite

The influence of pretreatment and activation conditions on anthracite activation was investigated. Separation of low ash coals by using dense media was conducted to obtain appropriate raw materials for activation. Activated carbons were produced from crushed and granule coals by physical activation (steam or CO₂) and physical activation with chemical pretreatment in mild and strong conditions. Microporous activated carbons having a surface area of 900 m₂/g were produced by steam activation from granules with 60% burn-off for 3 hrs of activation. Chemical pretreatment at the strong condition increased the surface area by 30% as compared with non-treated activated carbons. Chemical pretreatment, in general, affected activation degree, so pore volume increased by 20% and burn-off increased remarkably at the identical activation conditions. CO₂ activation was proven to be an effective method for producing microporous activated carbons having an average pore diameter of 20 å.     

Preparation and characterization of polymer‐based spherical activated carbons with tailored pore structure

A series of spherical activated carbons (SACs) with different pore structure were prepared from divinylbenzene‐based polymer through CO₂ activation. The effect of activation temperature and retention time on the yield and textural properties of the resulting SACs were studied. The SACs were characterized by N₂ adsorption, X‐ray diffraction, scanning electron microscopy, and aqueous adsorption assays. Either increasing activation temperature or extending retention time decreases the yield of SACs. The BET surface area and pore volume increase with activation temperature and reach a maximum at 1000°C and then decrease at higher activation temperatures. At 1000°C, BET surface area, total pore volume, and mesopore pore volume increase with retention time from 0.5 to 2 h, and meanwhile micropore volume decreases. The micropores are gradually widened into mesopores with increasing activation temperature or extending retention time. SEM and XRD analyses of SAC10 verify the presence of developed porous structure composed of disordered micrographite stacking. Aqueous adsorption assays indicate that SACs have good adsorption capacity for phenol. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Activated carbon from cherry stones by chemical activation: Influence of the impregnation method on porous structure

Cherry stones are utilized as a precursor for the preparation of activated carbons by chemical activation with phosphoric acid (H₃PO₄). The activation process typically consists of successive impregnation, carbonization, and washing stages. Here, several impregnation variables are comprehensively studied, including H₃PO₄ concentration, number of soaking steps, H₃PO₄ recycling, washing of the impregnated material, and previous semi-carbonization. The choice of a suitable impregnation methodology opens up additional possibilities for the preparation of a wide variety of activated carbons with high yields and tailored porous structures. Microporous activated carbons with specific surface areas of ～800 m² g^?1 are produced, in which > 60% of the total pore volume is due to micropores. High surface areas of ～1500 m² g^?1 can be also developed, with micropore volumes being a 26% of the total pore volume. Interestingly, using the same amount of H₃PO₄, either carbons with surface areas of 791 and 337 m² g^?1 or only one carbon with a surface area of 640 m² g^?1 can be prepared. The pore volumes range very widely between 0.07–0.55, 0.01–0.90, and 0.09–0.79 cm³ g^?1 for micropores, mesopores, and macropores, respectively.     

Synthesis of activated carbons by chemical activation of new anthracene oil-based pitches and their optimization by response surface methodology

This paper deals with the synthesis of new anthracene oil-based activated carbons by chemical activation with KOH. It focuses on the optimization of the processing conditions involved by means of surface response methodology. A factorial design (2³+3) in one block with four degrees of freedom was used to optimize the process, based on the responses BET surface area, total pore volume, mesopore volume, micropore volume and mol ratio CO:CO₂. The variables measured include KOH to pitch ratio (1:1, 3:1 and 5:1), activation temperature (700 up to 1000 °C) and pitch characteristics. The activation of anthracene oil-based pitch led to activated carbons with BET surface area values of 2880 m² g⁻¹. The factorial design expresses every response factor as a mathematical equation using the experimental variables. The most critical factor for each experiment design response has been identified from the analysis of variance (ANOVA). These mathematical models were also used to obtain the optimum processing conditions for the production of activated carbon with controlled properties. The experimental processing of the optimized activated carbons gave rise to a sample with BET, total pore volume, mesopore volume, micropore volume values which were in good agreement with those predicted by statistical analysis.     

Activated carbons from Uruguayan eucalyptus wood

Activated carbons were prepared from eucalyptus wood chars and the results of CO₂, CO₂-O₂ and steam activation were compared. The carbonization step gave rise to a narrow micropore structure and a highly developed macroporosity which increased slightly upon CO₂ activation and significantly upon steam activation. This last process led also to a widening of micropore size distribution and developed the mesoporosity more than CO₂ activation did. The presence of O₂ accompanying CO₂ in the activating gas increased the micro- and macroporosity of the carbons. No net destruction of microporosity was observed even at high burnoff levels and with as much as 5 vol. % O₂ in the activating gas.     

Enhancement of CO2 adsorption on phenolic resin-based mesoporous carbons by KOH activation

Carbons with high surface area and large volume of ultramicropores were synthesized for CO₂ adsorption. First, mesoporous carbons were produced by soft-templating method using triblock copolymer Pluronic F127 as a structure directing agent and formaldehyde and either phloroglucinol or resorcinol as carbon precursors. The resulting carbons were mainly mesoporous with well-developed surface area, large total pore volume, and only moderate CO₂ uptake. To improve CO₂ adsorption, these carbons were subjected to KOH activation to enhance their microporosity. Activated carbons showed 2–3-fold increase in the specific surface area, resulting from substantial development of microporosity (3–5-fold increase in the micropore volume). KOH activation resulted in enhanced CO₂ adsorption at 760 mmHg pressure: 4.4 mmol g⁻¹ at 25 °C, and 7 mmol g⁻¹ at 0 °C. This substantial increase in the CO₂ uptake was achieved due to the development of ultramicroporosity, which was shown to be beneficial for CO₂ physisorption at low pressures. The resulting materials were investigated using low-temperature nitrogen physisorption, CO₂ sorption, and small-angle powder X-ray diffraction. High CO₂ uptake and good cyclability (without noticeable loss in CO₂ uptake after five runs) render ultramicroporous carbons as efficient CO₂ adsorbents at ambient conditions.     

Effects of activation temperature on the properties and structure of PAN‐based activated carbon hollow fiber

Polyacrylonitrile (PAN) hollow fibers were pretreated with ammonium dibasic phosphate, then further oxidized in air, carbonized in nitrogen, and activated with carbon dioxide. The effects of activation temperature of a precursor fiber on the microstructure, specific surface, pore‐size distribution, and adsorption properties of PAN‐based activated carbon hollow fibers (PAN‐ACHF) were studied in this work. After the activation process, the BET surface area of the PAN‐ACHF and surface area of mesopores in the PAN‐ACHF increased very remarkably and reached 1422 m² g^?1 and 1234 m² g^?1, respectively, when activation temperature is 1000°C. The adsorptions to creatinine and VB₁₂ of PAN‐ACHF were much high and reached 99 and 84% respectively. In PAN‐ACHF which went through the activation at 700°C and 800°C, the micropore filling mainly occurred at low relative pressures, multimolecular layer adsorption occurred with the increasing of relative pressure, and the filling and emptying of the mesopores by capillary condensation occurred at high relative pressures. But in PAN‐ACHF which went through the activation at 900°C, a mass of mesopores resulted in the large pore filling by capillary condensation. The dominant pore sizes of mesopores in PAN‐ACHF are from 2 nm to 5 nm. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 3778–3783, 2006     

The characterization of microporosity in carbons with molecular sieve effects

The apparent and the real micropore size distributions (PSDs) of molecular sieve carbons can be assessed by combining the adsorption of CO₂ at 273 K with immersion calorimetry into liquids of increasing molecular dimensions. On the basis of model isotherms resulting from computer simulations, the adsorption of carbon dioxide, a relatively small probe, leads to the overall PSD of the carbon (essentially the internal micropore system). Immersion calorimetry, on the other hand, reveals the distribution of the pores accessible directly from the liquid phase, that is without constrictions. Liquid CS₂ probes the same volume as CO₂ and can be used as a reference. The paper describes the case of an industrial molecular sieve carbon obtained by blocking partly the entrance to a relatively broad micropore system, thus limiting its accessibility to molecules with diameters below 0.5–0.6 nm. It is shown how activation by steam at 900 °C removes the constrictions and leads to a gradual overlap of the two PSDs. The distribution of the pore widths on the surface, observed directly by scanning tunnelling microscopy, is also given.     

Potassium salt-assisted synthesis of highly microporous carbon spheres for CO2 adsorption

Highly microporous carbon spheres for CO₂ adsorption were prepared by using a slightly modified one-pot Stöber synthesis in the presence of potassium oxalate. Formaldehyde and resorcinol were used as carbon precursors, ammonia as a catalyst, and potassium oxalate as an activating agent. The resulting potassium salt-containing phenolic resin spheres were simultaneously carbonized and activated at 800 °C in flowing nitrogen. Carbonization of the aforementioned polymeric spheres was accompanied by their activation, which resulted in almost five-time higher specific surface area and total pore volume, and almost four-time higher micropore volume as compared to analogous properties of the carbon sample prepared without the salt. The proposed synthesis resulted in microporous carbon spheres having the surface area of 2130 m² g⁻¹, total pore volume of 1.10 cm³ g⁻¹, and the micropore volume of 0.78 cm³ g⁻¹, and led to the substantial enlargement of microporosity in these spheres, especially in relation to fine micropores (pores below 1 nm), which enhance CO₂ adsorption. These carbon spheres showed three-time higher volume of fine micropores, which resulted in the CO₂ adsorption of 6.6 mmol g⁻¹ at 0 °C and 1 atm.     

Enhanced mercury adsorption in activated carbons from biomass materials and waste tires

Agricultural residues and waste tires constitute an important source of precursors for activated carbon production. Activated carbons offer a potential tool for mercury emissions control. In this work, pine and oak wood, olive seed and tire wastes have been used for the preparation of activated carbons, in order to be examined for their mercury removal capacity. In the case of activated carbons produced from pine/oak woods and tire wastes, a two stage physical activation procedure was applied. Activated carbons derived from olive seeds were prepared by chemical activation using KOH. Pore structure of the samples was characterized by N₂ and CO₂ adsorption, while TPD-IR experiments were performed in order to determine surface oxygen groups. Hg° adsorption experiments were realized in a bench-scale adsorption unit consisting of a fixed-bed reactor. The influence of activation technique and conditions on the resulted activated carbon properties was examined. The effects of pore structure and surface chemistry of activated carbons were also investigated. Activated carbons produced from olive seeds with chemical activation possessed the highest BET surface area with well-developed micropore structure, and the highest Hg° adsorptive capacity. Oxygen surface functional groups (mainly lactones) seem to be involved in Hg° adsorption mechanism.