Mesoporous activated carbon and methods of producing same

Abstract

Mesoporous activated carbon is disclosed. In at least some embodiments, virgin activated carbon to be processed may be coconut shell-based. The enhanced activated carbon may have a mesopore structure of at least about 10%. The enhanced activated carbon may be produced through a calcium-catalyzed activation process. A chelator may also be used. Catalyzed thermal activation may be carried out until a desired mass loss is achieved.

What is claimed is: 
     
         1 . A method of producing an enhanced activated carbon, comprising:
 providing a predominantly microporous virgin activated carbon;   introducing an aqueous calcium-based catalyst to the virgin activated carbon to produce a catalyst impregnated activated carbon; and   heating the catalyst impregnated activated carbon at a pyrolysis temperature until a mesopore volume of at least about 10% is achieved while substantially maintaining a micropore structure associated with the virgin activated carbon to produce the enhanced activated carbon.   
     
     
         2 . The method of  claim 1 , wherein the method is associated with a mass loss of at least about 10%. 
     
     
         3 . The method of  claim 1 , wherein the aqueous calcium-based catalyst comprises calcium chloride. 
     
     
         4 . The method of  claim 1 , wherein the aqueous calcium-based catalyst comprises a chelator. 
     
     
         5 . The method of  claim 4 , wherein the chelator comprises citric acid. 
     
     
         6 . The method of  claim 1 , wherein the virgin activated carbon is coconut shell-based. 
     
     
         7 . The method of  claim 1 , wherein the virgin activated carbon is at least about 90% microporous. 
     
     
         8 . The method of  claim 1 , wherein the catalyst impregnated activated carbon is maintained at an intermediate temperature prior to reaching the pyrolysis temperature. 
     
     
         9 . The method of  claim 1 , wherein the virgin activated carbon is sprayed with or soaked in the aqueous calcium-based catalyst. 
     
     
         10 . The method of  claim 1 , further comprising oxidizing the catalyst impregnated activated carbon with carbon dioxide. 
     
     
         11 . The method of  claim 10 , wherein the catalyst impregnated activated carbon is oxidized with carbon dioxide and steam. 
     
     
         12 . A method of producing an enhanced activated carbon, comprising:
 providing a spent activated carbon having a calcium content of greater than or equal to about 0.5% by weight; and   heating the spent activated carbon to a pyrolysis temperature until a mesopore volume of at least about 10% is achieved to produce the enhanced activated carbon.   
     
     
         13 . The method of  claim 12 , wherein the spent activated carbon is predominantly microporous. 
     
     
         14 . The method of  claim 12 , wherein the spent activated carbon is coconut shell-based. 
     
     
         15 . The method of  claim 12 , further comprising oxidizing the spent activated carbon with at least one of carbon dioxide and steam. 
     
     
         16 . A method of facilitating water treatment, comprising:
 providing a vessel containing coconut shell-based activated carbon having a mesopore volume of at least about 10%; and   fluidly connecting a source of water to the reactor for treatment via contact with the coconut shell-based activated carbon.   
     
     
         17 . The method of  claim 14 , further comprising reactivating the coconut shell-based activated carbon after a predetermined time period. 
     
     
         18 - 20 . (canceled)