Upgraded activated carbons (ACs) are typically synthesized by mixed methods, such as solid–solid mixing and wet impregnation of low-grade ACs with KOH. This study compares the properties of upgraded ACs prepared by different methods using elemental analysis, X-ray photoelectron spectroscopy, N2 adsorption isotherms, and X-ray diffraction. In ACs produced by the solid–solid mixing, the ratio of potassium activator is proportional to the surface area and amount of gas produced. However, in wet impregnated ACs, the potassium ratio exhibits a zero or negative correlation. It is demonstrated that potassium ions in solution are not transferred to K2O and do not contribute to the surface area and pore size, generating less amount and different composition of gases. As such, impregnated ACs exhibit similar surface areas and large pores, regardless of the potassium ratio. The physical properties, such as specific surface areas and pore size distribution, of ACs using wet impregnation were similar to the ACs generated by the water physical activation. It indicated that the KOH does not efficiently act as a chemical activator in the wet impregnation method. Therefore, a certain amount and suitable mixing method of chemical activator play an important role in the property upgrade of ACs.

To prepare activated carbon with a high specific surface area, oxygen functional groups (OFGs) that can serve as useful electron donors during KOH activation were treated with nitric acid and incorporated into activated carbon. OFGs are incorporated differently according to the surface characteristics of starting materials. Up to 22.46% OFGs are incorporated into wood-based activated carbons (WACs), the C=O, COOH contents was 1.90, 17.05%, respectively. Whereas up to 12.82% OFGs are incorporated into coconut shell-based activated carbons, the C=O, COOH contents was 4.12, 6.15%, respectively. The OFGs used for increasing the specific surface area are the carbonyl group, and as the content of the functional group increases, the carbonyl group spreads to the carboxyl group. The specific surface area of activated carbons increased by 10–68% with an increase in the carbonyl group up to 6% (maximum point of carbonyl group). On the other hand, the specific surface area for WACs increased when the carboxyl group was 10% or below, but decreased by 6–15% when it increased to 10% or excess.

In this study, commercial activated carbons (ACs) were upgraded by different activation methods, and the gases generated during the activations were defined and quantified. The chemical activation commonly applied for upgrading ACs uses complex reactions, involving pyrolysis, physical, and chemical reactions. The ACs based on wood materials were characterized by elemental analysis, N2 physisorption, Fourier-transform infrared spectroscopy, X-ray photoelectron spectroscopy, and temperature-programmed desorption mass spectrometry. The patterns and composition of the generated gases were analyzed by gas chromatography and X-ray diffraction; high-resolution scanning electron microscopy was also used to characterize the activated carbon. The AC was mostly decomposed to CO2 by pyrolysis and physical activation, while CO was mainly detected during chemical activation from the K2CO3 produced by the reactions between CO2 and K2O. The detected amounts of generated gases were differed at various KOH ratios and residence times. The highest surface area obtained in this study was 2000 m2/g at the optimum ratio of AC and KOH (1:2).