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Activated Carbon

What is Activated

Activated carbon is a versatile, porous, irregularly structured material made primarily from carbon. It is naturally derived from sources like wood, coconut shells, or coal and features a range of pore sizes, from visible cracks to microscopic dimensions. With its large surface area, activated carbon is excellent for adsorbing and trapping molecules, making it useful in various adsorbent applications. It is crucial for removing impurities from gaseous and liquid media through a mechanism referred to as adsorption. Due to its extensive internal pore network and high surface area, activated carbon allows for high-efficiency adsorption.

Haycarb is one of the world's leading suppliers of powdered, granulated and extruded activated carbon.

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How Does Activated Carbon Work?

Activated carbon operates primarily through the process of adsorption, where contaminant molecules in a fluid phase (either gas or liquid) adhere to the surface of the carbon material. The large surface area given by its extensive network of pores results in numerous adsorption sites. As the contaminated fluid travels through the activated carbon, Van der Waals forces and other weak interactions attract and hold the contaminants in the pores. This effective trapping mechanism allows activated carbon to remove various organic and inorganic substances, including chemicals, toxins and odors, making it a powerful tool for purification and filtration.

Types of Activated Carbon

Powdered Activated Carbon (PAC)
Powdered activated carbons (PACs) typically have particle sizes ranging from 5 to 150 Å, though coarser and finer grades are also available. PACs are primarily used for liquid-phase adsorption. They are mixed into the liquid that needs treatment, and after adsorption, they are removed through sedimentation and filtration. PACs are generally used in batch processes because the amount added can be easily adjusted, and the powder can be easily removed. The advantages of PACs include lower processing costs and operational flexibility.
Granular activated carbons (GACs) are irregularly shaped particles created by milling and sieving, ranging in size from 0.2 mm to 5 mm. They are utilized in liquid and gas phase applications and fixed and moving systems. GACs are ideal for processes involving a single product refined or continuously produced in large quantities. They are coarse and longer-lasting than powdered activated carbons, easy to handle, and capable of purifying large volumes of gas or liquid with consistent quality. Additionally, GACs can be reactivated and reused multiple times.
The extrusion process produces coarse, cylindrical pellets ranging from 1 mm to 5 mm in diameter. Pelletized activated carbons are commonly used in solvent recovery, gas purification, and automotive emission control. The high-volume activity, low-pressure drop, and high strength of extruded carbon make it durable enough to last a vehicle’s lifespan.

Production Process of Activated Carbon

Coconut shells, peat, hard and soft wood, lignite coal, bituminous coal, other olive pits and carbonaceous materials are common raw materials used in activated carbon manufacturing. These materials are chosen based on the required features and the final product’s intended application.

Chemical Activation

Chemical activation is typically used for sawdust, wood, or peat. This method involves mixing and carbonization. Raw materials are combined with an activating agent, usually phosphoric acid, which swells the wood and opens the cellulose structure. The mixture is then dried and carbonized at 400-500°C in a rotary kiln. The acid prevents shrinkage, creating a porous structure with an extended surface area. Chemically activated carbons often require no further treatment and are used in powdered form.

Steam Activation

Steam activation is the most common method suitable for coconut shell and coal-based carbons. It involves two stages: carbonization and Activation. Raw materials are heated in an inert atmosphere (like flue gas) at high temperatures to dehydrate and devolatilize the carbon, creating a porous coke. During activation, the carbonized product is exposed to steam at 900-1100°C, enlarging the pores and increasing the internal surface area. This method allows customization of pore size for specific applications. The resulting activated carbon is processed into granular or powdered forms.

Properties of Activated Carbon

High Surface Area
Activated carbon has an extremely high surface area per unit volume, typically ranging from 500 to 1500 m²/g. This extensive surface area is due to its highly porous structure, allowing it to adsorb significant amounts of substances relative to its size.
Pore Structure
The efficacy of activated carbon largely depends on its pore size distribution, which includes micropores (less than 2 nm), mesopores (2-50 nm), and macropores (greater than 50 nm). This varied pore structure enables it to trap various contaminant molecules.
Adsorption Capacity
Due to its porous texture and surface chemistry, activated carbon can adsorb various organic molecules and some inorganic gases. This makes activated carbon highly effective in purifying liquids and gases by removing unwanted substances.

Why Choose Activated Carbon?

Cost Effectiveness
Due to its extensive pore structure and high efficiency in contaminant removal, activated carbon is a cost-effective adsorbent material. Its ability to be regenerated and reused multiple times makes it even more affordable, reducing the need for frequent replacements and lowering long-term operational costs.
Environmental Benefits
Activated carbon is essential for protecting the environment. It greatly minimizes pollution and cleanses air and water. It efficiently captures harmful pollutants and toxins, creating cleaner and safer surroundings. Additionally, activated carbon production utilizes natural waste materials like coconut shells, wood, and coal, supporting waste reduction and resource reuse while improving its environmental sustainability.
Versatility
Activated carbon is highly versatile and capable of adapting to various adsorption applications. This adaptability makes it invaluable across multiple industries, including water treatment, air purification, gold recovery, energy storage and chemical processing. Its variety in forms – such as granular, powdered, and pelletized – allows it to be customized for specific uses, ensuring optimal performance in diverse settings.

Selecting Activated Carbon for Your Application

Different shapes of activated carbon and system design

Activated carbon comes in various shapes – granular, powdered and pelletized – each optimized for different systems and applications. Granular activated carbon (GAC) is suited for water treatment because it can handle lower pressure drops and higher flow rates. Powdered activated carbon (PAC) is ideal for batch processes or rapid adsorption needs like waste treatment. Pelletized carbon, known for its high density, uniform particle size and low dust content, is preferred for air purification, where minimal pressure drop is crucial. Effective carbon selection must also consider system design, including factors such as flow rate, contact time, and the type of bed (fixed, moving, or fluidized), to ensure optimal interaction with contaminants and prolong system efficiency and durability. Therefore, the selection of activated carbon must be aligned with both the physical properties of the carbon and the specific operational parameters of the system it will be utilized in.

Particle size directly influences the flow dynamics and pressure drop across the carbon bed; smaller particles typically provide a larger surface area but can also lead to higher pressure drops, which might be undesirable in applications with flow limitations. On the other hand, adsorption kinetics, which describes the rate at which contaminants are removed from the fluid being treated, is crucial for ensuring efficient purification. Faster kinetics are generally preferred, as they allow for quicker contaminant removal, which can be essential in applications requiring rapid processing times.

Selecting activated carbon based on pore size distribution is essential for aligning the carbon’s properties with specific adsorption needs. Pore sizes are divided into micropores (less than 2 nm), mesopores (2-50 nm), and macropores (over 50 nm). With its extensive surface area, microporous carbon is ideal for adsorbing small molecular contaminants like gases and volatile compounds. Mesoporous and macroporous carbons are more suitable for larger molecules in liquid-phase applications, such as colors and odors.

In addition to pore size, other crucial factors include total surface area, pore volume, and the surface’s chemical nature. These factors impact the carbon’s affinity for various contaminants and overall adsorption capacity. Ensuring compatibility between the carbon’s properties and the specific contaminants and medium is vital for effective purification.

At Haycarb PLC, our team of experts is dedicated to helping you find the most effective purification solutions customized to your specific requirements. We specialize in offering Coconut Shell Based Activated Carbon, known for its superior performance and sustainability, alongside professional guidance in selecting the perfect activated carbon from our wide range of products. Our solutions are designed to align seamlessly with your processes, ensuring operational excellence while promoting environmental sustainability.

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