The invention relates to a method for the production of activated carbon, in particular particulate activated carbon, having an increased mesopore and/or macropore volume fraction preferably having an increased mesopore volume fraction.

Provided herein are apparatuses, systems, and methods useful for continuous thermolysis of carbonaceous matter. In certain aspects and embodiments, the invention presents continuous thermolysis of carbonaceous matter in a controlled temperature and steam environment to produce a low volatility char, with subsequent steam activation of the char under pressure producing activated carbon and pressurized syn-gas, all of which are carried out in a reactor system including one or more vessels. The syn-gas is enriched in hydrogen in a high temperature shift reactor and separated in a pressurized swing adsorber to provide a pressurized pure hydrogen stream and a low-pressure combustible tail gas.

Provided herein are apparatuses, systems, and methods useful for continuous thermolysis of carbonaceous matter. In certain aspects and embodiments, the invention presents continuous thermolysis of carbonaceous matter in a controlled temperature and steam environment to produce a low volatility char, with subsequent steam activation of the char under pressure producing activated carbon and pressurized syn-gas, all of which are carried out in a reactor system including one or more vessels. The syn-gas is enriched in hydrogen in a high temperature shift reactor and separated in a pressurized swing adsorber to provide a pressurized pure hydrogen stream and a low-pressure combustible tail gas.

The disclosure provides a system and method for production of activated carbon from a coal-originating particulate feed material. Feed material and activating gas are introduced into a reaction chamber, the activating gas being introduced at a velocity above the average terminal velocity of particles within the feed material. Feed material is then entrained in the activating gas such that a recirculating flow path for the feed material is established within the reaction chamber. Activated material may then be recovered from the chamber.

The disclosure provides a system and method for production of activated carbon from a coal-originating particulate feed material. Feed material and activating gas are introduced into a reaction chamber, the activating gas being introduced at a velocity above the average terminal velocity of particles within the feed material. Feed material is then entrained in the activating gas such that a recirculating flow path for the feed material is established within the reaction chamber. Activated material may then be recovered from the chamber.

A method for preparing high specific surface area activated carbon through rapid activation, comprises the following steps: 1) selecting biomass raw material with a particle size of 0.3-0.9 mm; immersing the biomass raw material in a chemical reagent for 3-6 hours; and drying the biomass raw material in a constant-temperature drying oven of 100 C.-150 C. after immersing is ended; 2) stirring or crushing the dried material to form granular material after drying is completed; and 3) adopting a fluidized bed or a spouted bed as an activation reactor; increasing the temperature of the activation reactor to 700-800 C.; introducing fluidized gas; placing quartz sand; placing the granular material obtained in step 2); activating for 1-10 min; immediately discharging the material after activation is ended; and washing the material with water until the material is neutral to obtain activated carbon with a specific surface area of 1267-1359 m.sup.2/g.

Biogenic activated carbon compositions disclosed herein comprise at least 55 wt % carbon, some of which may be present as graphene, and have high surface areas, such as Iodine Numbers of greater than 2000. Some embodiments provide biogenic activated carbon that is responsive to a magnetic field. A continuous process for producing biogenic activated carbon comprises countercurrently contacting, by mechanical means, a feedstock with a vapor stream comprising an activation agent including water and/or carbon dioxide; removing vapor from the reaction zone; recycling at least some of the separated vapor stream, or a thermally treated form thereof, to an inlet of the reaction zone(s) and/or to the feedstock; and recovering solids from the reaction zone(s) as biogenic activated carbon. Methods of using the biogenic activated carbon are disclosed.

Biogenic activated carbon compositions disclosed herein comprise at least 55 wt % carbon, some of which may be present as graphene, and have high surface areas, such as Iodine Numbers of greater than 2000. Some embodiments provide biogenic activated carbon that is responsive to a magnetic field. A continuous process for producing biogenic activated carbon comprises countercurrently contacting, by mechanical means, a feedstock with a vapor stream comprising an activation agent including water and/or carbon dioxide; removing vapor from the reaction zone; recycling at least some of the separated vapor stream, or a thermally treated form thereof, to an inlet of the reaction zone(s) and/or to the feedstock; and recovering solids from the reaction zone(s) as biogenic activated carbon. Methods of using the biogenic activated carbon are disclosed.

The present disclosure provides biorefining systems for co-producing activated carbon along with primary products. A host plant converts a feedstock comprising biomass into primary products and carbon-containing co-products; a modular reactor system pyrolyzes and activates the co-products, to generate activated carbon and pyrolysis off-gas; and an oxidation unit oxidizes the pyrolysis off-gas, generating CO.sub.2, H.sub.2O, and energy. The energy is recycled and utilized in the host plant, and the CO.sub.2 and H.sub.2O may be recycled to the reactor system as an activation agent. The host plant may be a saw mill, a pulp and paper plant, a corn wet or dry mill, a sugar production facility, or a food or beverage plant, for example. In some embodiments, the activated carbon is utilized at the host plant to purify one or more primary products, to purify water, to treat a liquid waste stream, and/or to treat a vapor waste stream.

The present disclosure provides biorefining systems for co-producing activated carbon along with primary products. A host plant converts a feedstock comprising biomass into primary products and carbon-containing co-products; a modular reactor system pyrolyzes and activates the co-products, to generate activated carbon and pyrolysis off-gas; and an oxidation unit oxidizes the pyrolysis off-gas, generating CO.sub.2, H.sub.2O, and energy. The energy is recycled and utilized in the host plant, and the CO.sub.2 and H.sub.2O may be recycled to the reactor system as an activation agent. The host plant may be a saw mill, a pulp and paper plant, a corn wet or dry mill, a sugar production facility, or a food or beverage plant, for example. In some embodiments, the activated carbon is utilized at the host plant to purify one or more primary products, to purify water, to treat a liquid waste stream, and/or to treat a vapor waste stream.