Chemical activation consumes copious quantities of chemicals is therefore hampered by its low economic feasibility. However, this issue can be overcome through the recovery and reuse of alkali compounds leached into wastewater. Because the leached potassium compounds exist as the relatively less reactive K2CO3, we explored three different approaches to remove carbonate ions ( CO3 2−) from the wastewater: (i) CO₂ stripping after acidification, (ii) exchanging CO₃2⁻ for OH⁻ using strong basic anion exchange resins, and (iii) inducing a phase transition via a reaction with Ca(OH)2 to precipitate CaCO3. Both ion exchange and phase transition convert K2CO3 into highly reactive potassium compounds such as KOH. The phase transition effectively enhanced the specific surface area of the activated carbon and thus had implications for pore development in carbon precursors, while offering a viable recovery strategy for alkali compounds that reduces costs by approximately 20% compared to traditional methods. These findings suggest that the in-situ recycling of wastewater for the production of activated carbon can improve the economic viability of manufacturing processes.

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).