In this work, the sulfonic acid group was introduced into the resorcinol–formaldehyde (RF) microspheres by the addition of p-phenolsulfonic acid during the polycondensation process of RF. The hydrophilicity of the sulfonated RF allowed KOH to infiltrate inside the microspheres, which enhanced the formation of mesopores in the carbon microspheres during the activation process by KOH. SEM and TEM observations and N2 adsorption measurements verified the formation of abundant mesopores in the porous carbon microspheres. The BET surface area of these mesoporous carbons exceeded 2000 m2/ g. In 17 m NaClO4 “water-in-salt” (WIS) electrolyte-based supercapacitor, the synthesized mesoporous carbon exhibited high specific capacitance of 170 F/g at current density of 0.5 A/g, comparable to those in regular KOH electrolyte. When graphite was used as current collectors, the symmetric cell could operate at 2.5 V, and the mesoporous carbon exhibited an energy density of 43 Wh/kg at power density of 0.25 kW/kg, and 25 Wh/kg at power density of 6.25 kW/kg, respectively, which were superior to those using Pt or stainless steel as current collectors. The mesoporous carbon/graphite was an excellent electrode in new-generation “WIS” electrolyte-based high-voltage supercapacitor due to their high energy and power density.

This research aims to study the effect of impregnation ratio and activation temperature on microporous development of activated carbon (AC). Rubberwood chips, which are wasted from home furnishing industry, were used as precursors for synthesized of activated carbon by chemical activation employing Potassium hydroxide (KOH) as activation agent. Rubberwood char was carbonized at 400 °C for 1 h under inert gas. In this experiment, the rubberwood chars were impregnated with KOH solution by 1:1–3 (char: KOH) impregnation ratio for 24 h, then the samples were activation at 600–800 °C. Surface area, pore volume, micropore volume, pore size distribution, adsorption isotherm and porous structure were analyzed in this experiment to identify the properties of derived activated carbon. According to the investigation, the activated carbon, activated at 800 °C with impregnation ratio of 1:3, demonstrated the highest surface area, pore volume and micropore volume as 1491.75 m2/g, 0.6777 cm3/g, and 0.5813 cm3/g, respectively. Its average pore size was 1.82 nm and it also showed type I adsorption isotherm which indicates as microporous solid.

The simultaneous use of KOH and nitrogen to manufacture carbon materials provides these materials with properties that the presence of only one of these additives would not give them, such as high porosity and reactivity. However, it is difficult to obtain nitrogen-doped carbon materials with both high porosity and high nitrogen content, as the KOH significantly reduces the nitrogen content. In this review the complex relationships between nitrogen content and nitrogen precursor amount, KOH amount and the activation temperature are discussed, with a focus on the different N-functional groups and the porosity of the fabricated carbons. Generally, increasing activation temperature and increasing KOH amount decrease the nitrogen content due to reactions with the N-containing substructures of carbon, resulting in the release of nitrogen as N2, HCN and other N gases. Increasing these parameters can also result in the reduction of pyridine-N while the amount of quaternary-N increases simultaneously. Besides this, an increase in the amount of nitrogen precursor leads to an increase in the porosity of N-doped materials. However, too high amounts of the nitrogen precursor generate an excess of nitrogen which blocks the pore system and consequently reduces the porosity of the doped carbons.

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.

Nitrogen-doped carbons have attracted much attention due to their novel application in relation to gas storage. In this study, nitrogen-doped porous carbons were synthesized using SBA-15 as a template, polypyrrole as the carbon and nitrogen precursor, and KOH as an activating agent. The effect of the activation temperature (600–850°C) on the CO2 adsorption capacity of the obtained porous carbons was studied. Characterization of the resulting carbons showed that they were micro-/meso-porous carbon materials with a well-developed pore structure that varied with the activation temperature. The highest surface area of 1488 m2 g–1 was achieved at an activation temperature of 800°C (AC-800). The nitrogen content of the activated carbon decreased from 4.74 to 1.39 wt% with an increase in the activation temperature from 600 to 850°C. This shows that nitrogen is oxidized and more easily removed than carbon during the activation process, which indicates that C-N bonds are more easily ruptured at higher temperatures. Furthermore, CO2 adsorption isotherms showed that AC-800 exhibited the best CO2 adsorption capacity of 110 mg g–1 at 298 K and 1 bar.

In order to prepare high-quality activated carbons (ACs), coal tar pitch (CTP), and mixtures of CTP and petroleum pitch (PP) were activated with KOH. The ACs prepared by activation of CTP in the range of 700~1000℃ for 1~5 h had very porous textures with large specific surface areas of 2470~3081 m2/g. The optimal activation conditions of CTP were determined as CTP/KOH ratio of 1:4, activation temperature of 900℃, and activation time of 3 h. The obtained AC showed the highest micro-pore volume, and pretty high specific surface area and meso-pore volume. The micro-pore volumes and specific areas of activated mixtures of CTP and PP were similar to each other but the meso-pore volume could be increased. In order to change the degree of crystallinity of precursors before KOH activation process, the CTPs were carbonized in the range of 500~900℃. As the carbonization temperature increased, the specific surface area and pore volume of the activated ACs with the same activation conditions for CTP decreased dramatically. It was demonstrated that the increased pore size distribution of AC electrodes in the range of 1 to 2 nm plays an important role in the performance of electric double-layer capacitor.

The production of functional activated carbon materials starting from inexpensive natural precursors using environmentally friendly and economically effective processes has attracted much attention in the areas of material science and technology. In particular, the use of plant biomass to produce functional carbonaceous materials has attracted a great deal of attention in various aspects. In this study the preparation of activated carbon has been attempted from rice husks via a chemical activation-assisted microwave system. The rice husks were milled via attrition milling with aluminum balls, and then carbonized under purified N2. The operational parameters including the activation agents, chemical impregnation weight ratio of the calcined rice husk to KOH (1:1, 1:2 and 1:4), microwave power heating within irradiation time (3-5 min), and the second activation process on the adsorption capability were investigated. Experimental results were investigated using XRD, FT-IR, and SEM. It was found that the BET surface area of activated carbons irrespective of the activation agent resulted in surface area. The activated carbons prepared by microwave heating with an activation process have higher surface area and larger average pore size than those prepared by activation without microwave heating when the ratio with KOH solution was the same. The activation time using microwave heating and the chemical impregnation ratio with KOH solution were varied to determine the optimal method for obtaining high surface area activated carbon (1505 m2/g).

Four activated carbons were produced by two-stage process as followings; semi-carbonization of indigenous biomass waste, i.e. cotton stalks, followed by chemical activation with KOH under various activation temperatures and chemical ratios of KOH to semi-carbonized cotton stalks (CCS). The surface area, total pore volume and average pore diameter were evaluated by N2-adsorption at 77 K. The surface morphology and oxygen functional groups were determined by SEM and FTIR, respectively. Batch equilibrium and kinetic studies were carried out by using a basic dye, methylene blue as a probe molecule to evaluate the adsorption capacity and mechanism over the produced carbons. The obtained activated carbon (CCS-1K800) exhibited highly microporous structure with high surface area of 950 m2/g, total pore volume of 0.423 cm3/g and average pore diameter of 17.8 a. The isotherm data fitted well to the Langmuir isotherm with monolayer adsorption capacity of 222 mg/g for CCS-1K800. The kinetic data obtained at different concentrations were analyzed using a pseudo-first-order, pseudo-second-order and intraparticle diffusion equations. The pseudo-second-order model fitted better for kinetic removal of MB dye. The results indicate that such laboratory carbons could be employed as low cost alternative to commercial carbons in wastewater treatment.

Carbon nanofiber (CNF) grown catalytically was chemically activated with KOH to attain structural change of CNF. The structural changes of CNF through KOH activation were investigated by using BET and SEM. From the results of BET, it was found that KOH activation was effective to develop particular sizes of pores on the CNF surface, increasing the surface area of CNF. Activated CNF was applied as an anode catalyst support of fuel cell. The effects of different activation conditions including the activation temperature and the activation time on the specific surface area of the CNF activated with KOH were investigated to obtain appropriate structure as a catalyst support. The 60 wt% Pt-Ru catalyst prepared was observed by using TEM and XRD.

OXI-PAN fibers, Kynol fibers and rayon fibers were used as precursorsfor the preparation of activated carbon fibers (ACFs) by chemical activation with KOH at 800℃. The effects of different precursorfibers and fiber/KOH ratios on the final ACFs are discussed. The precursor fibers used are appropriate for the ACFs in a single stage pyrolysis process. The OXI-PAN fibers which were activated with KOH of 2.0M showed a specific surface area of 2328m2/g however, loosed the fiber shape because of low yields. The Kynol fibers and Rayon fibers showed the high yields but the lower specific surface area of 900m2/g and 774m2/g, respectively, at KOH of 1.5M. The OXI-PAN fibers which were activated with KOH of 1.5M have a specific surface area of 1028m2/g and higher micro-pore volumes and lower yields rather than Kynol-1.5 and Rayon-1.5 samples. This phenomenon is because of higher chemical resistance of the Kynol and Rayon fibers rather than OXI-PAN fibers. However, the Kynol fibers were the best precursors on KOH activation at 800℃ considered carbon yields, surface areas and micropore volumes.

The role of KOH in the one-stage KOH-activation of rice straws was studied using FTIR, XPS, TGA, and DTG techniques.It was found that at the impregnation, KOH extracts to some extent the lignin component from rice straw and reacts withhydroxyl groups. On heat-treatment, the impregnated KOH facilitates intermolecular condensation reaction on one hand butretards the thermal degradation of cellulose molecules on the other hand. The oxygen-containing surface functional groupsnewly created by oxidation of KOH may facilitate the bulk, not controlled, consumption of carbon atoms so that the effectiveporosities may not be able to be developed by the one-stage activation process.

Naphtha cracking bottom oil was reformed with heat treatment and then spun at 310℃. These pitch-based carbon fibers were carbonized at 1000℃ after oxidation at 280℃, for 90 min. These fibers were chemically activated with molar ratio of KOH/CF (1 : 1) at different temperatures (250~900℃) for 1 hr. The process of activation was characterized with DTA, TGA, BET surface area and pore size distribution. The activation of fibers by KOH was performed by several process. One is the reduction process that carbon fiber was reacted with K2O produced from dehydration process above 400℃. The other is the process that K2CO3 was directly reacted with carbon fiber. At 800℃, the activation was performed by catalyzed mechanism that K2O was obtained from the reaction of metal potassium with CO2, then was changed to K2CO3. At 870℃, the activation was also observed that activation mechanism was promoted by metal catalyst with CO2 from decomposition of K2CO3. The specific surface area of prepared activated carbon fibers was dependent on the activation mechanism. The specific surface area was in the range of 1519~2000 cm3/g and was the largest prepared at 870℃. The pores developed were mostly micropores which was very narrow and uniform. The total pore volume was 0.58~0.77 cm3/g.