Preparation of porous carbons from thermoplastic precursors and their performance for electric double layer capacitors

Porous carbons with high surface area were successfully prepared from thermoplastic precursors, such as poly(vinyl alcohol) (PVA), hydroxyl propyl cellulose and poly(ethylene terephthalate), by the carbonization of a mixture with MgO at 900 °C in an inert atmosphere. After carbonization the MgO was dissolved out using a diluted sulfuric acid and the carbons formed were isolated. The mixing of the PVA carbon precursor with the MgO precursors (reagent grade MgO, magnesium acetate or citrate) was done either in powder form or in an aqueous solution. The BET surface area of the carbons obtained via solution mixing could reach a very high value, such as 2000 m²/g, without any activation process. The pore structure of the resultant carbons was found to depend strongly on the mixing method; the carbons prepared via solution mixing were rich in mesopores, but those produced via powder mixing were rich in micropores. The size of mesopores was found to be almost the same as that of the MgO particles, suggesting a way of controlling the mesopore size in the resultant carbons. Measurement of capacitance was carried out in 1 mol/L H₂SO₄ electrolyte. The porous carbon with a BET surface area of 1900 m²/g prepared at 900 °C through solution mixing of Mg acetate with PVA showed a fairly high EDLC capacitance, about 250 F/g with a current density of 20 mA/g and 210 F/g with 1000 mA/g. The rate performance was closely related to the mesoporous surface area.     

Metal-organic framework (MOF) as a template for syntheses of nanoporous carbons as electrode materials for supercapacitor

Five nanoporous carbons (NPCs) were prepared by polymerizing and then carbonizing carbon precursor of furfuryl alcohol accommodated in a porous metal-organic framework (MOF-5, [Zn₄O(bdc)₃], bdc = 1,4-benzenedicarboxylate) template. The Brunauer-Emmett-Teller (BET) surface areas for five NPC samples obtained by carbonizing at the temperatures from 530 to 1000 °C fall into the range from 1140 to 3040 m² g⁻¹ and the dependence of BET surface areas on carbonization temperatures shows a “V” shape. All the five NPC samples have a pore size distribution centered at about 3.9 nm. As electrode materials for supercapacitor, the NPC samples obtained at the temperatures higher than 600 °C display the ideal capacitor behaviors and give rise to almost constant specific capacitance (above 100 F g⁻¹ at 5 mV s⁻¹) at various sweep rates, which is associated with their mesoporous characteristics. However, the NPC sample with the highest BET surface area (3040 m² g⁻¹) obtained by carbonizing at 530 °C gives a unusually low capacitance (12 F g⁻¹ at 5 mV s⁻¹), which may be attributed to the poor conductivity of the carbon material due to the low carbonization temperature.     

Preparation of microporous sorbents from cedar nutshells and hydrolytic lignin

Carbon nutshells and hydrolytic lignin were used as starting materials for the preparation of microporous active carbons. Optimum parameters for cedar nutshell carbonization have been selected (temperature of carbonization 700-800 °C, rate of heating less than 3 °C/min) for the preparation of microporous carbons (average pore width 0.56 nm). The textural characteristics of microporous carbons made from nutshell are similar to those of a ‘Coconut’ carbon molecular sieve, but the latter has both a higher CO₂ adsorption capacity and a higher coefficient of N₂/O₂ separation. The influence of carbonization and steam-activation parameters on the microtexture and molecular-sieve properties of granular carbons made from hydrolytic lignin was also investigated. A low rate of heating (less 3 °C/min) promotes the formation of micropores with average sizes around 0.56-0.58 nm at carbonization temperature 700 °C. At the same carbonization temperature the average sizes of micropores were 0.7-0.78 nm at rates of heating more than 3 °C/min. The activation of lignin-char with steam at 800 °C resulted in the formation of active carbons with more developed micropore volume (0.3-0.35 cm³ g⁻¹) and with micropores of widths around 0.6-0.66 nm which are able to separate He from a He-CH₄ mixture. The size of the micropores was varied as a function of burn off value.     

Synthetic carbons activated with phosphoric acid: II. Porous structure

Synthetic activated carbons were prepared by H₃PO₄ activation of a chloromethylated and sulfonated copolymer of styrene and divinylbenzene, using an impregnation weight ratio of 0.75 and carbonization temperatures in the 400-1000 °C range. Other impregnation ratios (0.93 and 1.11) were also used at a carbonization temperature of 800 °C. The porous texture of the resulting carbons was characterized by N₂ adsorption at −196 °C and CO₂ adsorption at 0 °C. All carbons exhibited a multimodal pore size distribution with maxima in the micropore and meso/macropore regions. Maxima in pore volume were attained at 900 °C for micropores and at 500 and 900 °C for mesopores. The mesopore volume was less sensitive than the micropore volume to changes in the impregnation ratio. It is concluded that the porous texture is not a prime factor in determining the outstanding cation exchange capacities of these carbons.     

Effect of pore size distribution of coal-based activated carbons on double layer capacitance

A series of coal-based activated carbons representing a wide range of mesopore content, from 16.7 to 86.9%, were investigated as an electrode in electric double layer capacitors (EDLCs) in 1 mol l⁻¹ H₂SO₄ and 6 mol l⁻¹ KOH electrolytic solutions. The activated carbons (ACs) used in this study were produced from chemically modified lignite, subbituminous and bituminous coals by carbonization and subsequent activation with steam. The BET surface area of ACs studied ranged from 340 to 1270 m² g⁻¹. The performance of ACs as EDLC electrodes was characterized using voltammetry, galvanostatic charge/discharge and impedance spectroscopy measurements. For the carbons with surface area up to 1000 m² g⁻¹, the higher BET surface area the higher specific capacitance (F g⁻¹) for both electrolytes. The surface capacitance (μF cm⁻²) increases also with the mesopore content. The optimum range of mesopore content in terms of the use of ACs studied for EDLCs was found to be between 20 and 50%. A maximum capacitance exceeding 160 F g⁻¹ and a relatively high surface capacitance about 16 μF cm⁻² measured in H₂SO₄ solution were achieved for the AC prepared from a sulfonated subbituminous coal. This study shows that the ACs produced from coals exhibit a better performance as an electrode material of EDLC in H₂SO₄ than in KOH electrolytic solutions. For KOH, the capacitance per unit mesopore surface is slightly lower than that referred to unit micropore surface (9.1 versus 10.1 μF cm⁻²). However, in the case of H₂SO₄ the former capacitance is double and even higher compared with the latter (23.1 versus 9.8 μF cm⁻²). On the other hand, the capacitance per micropore surface area is the same in both electrolytes used, about 10.0 μF cm⁻².     

Improvement of the structural and chemical properties of a commercial activated carbon for its application in electrochemical capacitors

The present paper shows that the performance of an inexpensive activated carbon used in electrochemical capacitors can be significantly enhanced by a simple treatment with KOH at 850 °C. The changes in the specific surface area, as well as in the surface chemistry, lead to high capacitance values, which provide a noticeable energy density.The KOH-treatment of a commercial activated carbon leads to highly pure carbons with effective surface areas in the range of 1300-1500 m² g⁻¹ and gravimetric capacitances as high as three times that of the raw carbon.For re-activated carbons, one obtains at low current density (50 mA g⁻¹) values of 200 F g⁻¹ in aqueous electrolytes (1M H₂SO₄ and 6M KOH) and around 150 F g⁻¹ in 1M (C₂H₅)₄NBF₄ in acetonitrile. Furthermore, the resulting carbons present an enhanced and stable performance for high charge/discharge load in organic and aqueous media.This work confirms the possibilities offered by immersion calorimetry on its own for the prediction of the specific capacitance of carbons in (C₂H₅)₄NBF₄/acetonitrile. On the other hand, it also shows the limitations of this technique to assess, with a good accuracy, the suitability of a carbon to be used as capacitor electrodes operating in aqueous electrolytes (H₂SO₄ and KOH).     

Experimental evidence of an upper limit for hydrogen storage at 77 K on activated carbons

An upper limit for hydrogen storage at 77 K on activated carbons was clearly observed in the present experimental work. Such a limit is around 6.4 wt.%, i.e., close to the theoretical limit of 6.8 wt.%. Results of hydrogen storage were obtained in three independent laboratories using volumetric and gravimetric devices. Lab-made activated carbons (ACs) were found to have higher capacities than those of the commercial material AX-21. A maximum excess hydrogen storage capacity of 6.0 wt.% at 77 K and 4 MPa was obtained. This maximum was reduced to 0.6 wt.% at 298 K and 5 MPa. ACs with surface areas (S_BET) as high as 3220 m² g⁻¹ were prepared from chemical activation of anthracites with alkali (Na and K) hydroxides. At 77 K and 4 MPa, excess hydrogen storage capacity was directly correlated with S_BET for ACs having S_BET values lower than 2630 m²/g. Hydrogen uptake at 77 K also correlated with micropore volume and strongly depended on average pore diameter.     

Effect of activation time on the properties of activated carbons prepared by microwave-assisted activation for electric double layer capacitors

Activated carbons (ACs) were prepared by microwave-assisted heat treatment of petroleum coke with KOH as activation agent, and characterized by infrared spectroscopy and nitrogen adsorption technique with the aim of studying the effect of activation time on the properties of ACs for electrodes in electric double layer capacitors (EDLCs). The electrochemical properties of AC electrodes in EDLCs were studied by cyclic voltammetry, constant current charge-discharge and electrochemical impedance spectroscopy. The results show that the specific surface area (S_BET) and total pore volume of ACs goes through a maximum as the activation time increases. At 35 min of the activation time, the as-made AC (denoted as AC-35) has a S_BET of 2312 m²/g. With AC-35 as the electrode, its specific capacitance in EDLC at a current density of 50 mA/g can reach 342.8 F/g, and remains at 245.6 F/g even after 800 cycles while the energy density of the capacitor remains at 8.0 Wh/kg. The results have demonstrated that the microwave-assisted heat treatment is an efficient approach to the preparation of ACs with high performance for EDLCs.     

Carbons with narrow pore size distribution prepared by simultaneous carbonization and self-activation of tobacco stems and their application to supercapacitors

Highly microporous carbons with narrow pore size distribution have been prepared by simultaneous carbonization and self-activation of tobacco wastes at temperatures ranging from 600 to 1000 °C. The efficiency of porosity development, without pores broadening, is attributed to well-distributed alkalis at the molecular level in the tobacco precursor. With Burley tobacco, the BET specific surface area and average micropore size L₀ increased up to 800 °C (Burley 800), where the values reached maxima of 1749 m² g⁻¹ and 1.2 nm, respectively. At temperatures higher than 800 °C, annealing of the materials dominates and provokes a decrease of S_BET and L₀. Burley carbons were implemented in supercapacitors using 1 mol L⁻¹ aqueous Li₂SO₄ or 1 mol L⁻¹ TEABF₄ in acetonitrile. In both electrolytes, the capacitance of Burley carbons followed the same trend as S_BET and L₀. Burley 800 demonstrated outstanding capacitance values of 167 F g⁻¹ (at 0.8 V limit) and 141 F g⁻¹ (at 2.3 V limit) in 1 mol L⁻¹ aqueous Li₂SO₄ and 1 mol L⁻¹ TEABF₄, respectively. Such values, about 50% higher as compared to commercially available carbons, are attributed to the narrow pore size distribution of this carbon with a maximum of pores around 1.2 nm close to the size of solvated ions in these electrolytes.     

KOH activation of pitch-derived carbonaceous materials—Effect of carbonization degree

Two series of mesophase pitches and semi-cokes of different carbonization degree were produced by heat treatment of anthracene oil derived pitches P1 and P4 in the temperature range of 460-700 °C. These carbonaceous materials were activated with potassium hydroxide at 700 °C using 1:3 reagents ratio to assess the effects of the precursor optical texture and carbonization degree on the activation behavior. The results show that the increase in the pitch pretreatment temperature suppresses propensity to the pore generation while enhancing particle breaking. The effect can be illustrated by decreases in the BET surface area S_BET from ~ 2700 to ~ 1500 m² g⁻¹ and the micropore volume V_DR from ~ 0.85 to ~ 0.45 cm³ g⁻¹. These parameters are inversely related with the H/C atomic ratio of precursor. In contrast, the anisotropic development of pitch coke, varying from flow type to mosaics, has a slight effect on the activation behaviour. The mechanism of porosity generation, that is proposed, stresses the role of hydrogen occurring at the edges of graphene layers and potassium metal insertion/deinsertion on the porosity development and particle disintegration during KOH activation of pitch-derived carbons.     

Preparation of microporous carbon films from fluorinated aromatic polyimides

Pyrolysis and carbonization behaviors of fluorinated aromatic polyimide films synthesized from fluorinated dianhydrides and diamines were investigated by thermogravimetric and mass spectrometric measurements. Evolution of fluorine compound gases and related species was observed during the pyrolysis in the temperature range from 450 to 700 °C, in addition to the evolution of CO and CO₂ due to the imide ring degradation. By the carbonization of these fluorinated polyimides at 600-1000 °C, highly microporous carbons were obtained without any activation process, of which adsorption/desorption isotherm of N₂ gas was typical type I and pore size distribution was sharp at around 0.55 nm in width. Surface area increased with increasing fluorine content in the repeating unit of fluorinated polyimide: the polyimide with the highest fluorine content of 31.3 mass% gave a high microporous surface area of 1342 m² g⁻¹ and micropore volume of 0.44 mL g⁻¹.     

Activated carbon fiber cloths as electrodes for high performance electric double layer capacitors

Activated carbon fiber cloth (ACFC) electrodes with high double layer capacitance and good rate capability were prepared from polyacrylonitrile (PAN) fabrics by optimizing the carbonization temperature prior to CO₂ activation. The carbonization temperature has a marked effect on both the pore structure and the electrochemical performances of the ACFCs. Moderate carbonization at 600 °C results in higher specific surface area and larger pore size, and hence higher capacitance and better rate capability. The specific capacitance of the ACFCs in 6 mol L⁻¹ KOH aqueous solution can be as high as 208 F g⁻¹. It remains 129 F g⁻¹ as the current density increases to 10 000 mA g⁻¹.     

Swelling and related mechanical and physical properties of carbon nanofiber filled mesophase pitch for use as a bipolar plate material

Mesophase pitch was investigated as a melt processable precursor to a compression or injection moldable all carbon bipolar plate. After shaping, carbonization to 1000 °C or greater is required to achieve the desired electrical and mechanical properties, but gases evolved during this step lead to swelling. Carbon nanofiber was added to suppress swelling during carbonization and bypass the typical oxidation steps used when processing mesophase pitch. The addition of carbon nanofiber decreased swelling by increasing the viscosity of the melt. Carbonized materials with carbon nanofibers can show strengths (30-50 MPa) and conductivities (20-80 S cm⁻¹) consistent with composite bipolar plate materials. The materials show conductivities below Department of Energy target values at the current carbonization temperatures, which were limited to 1000 °C. The use of glass fibers as a secondary filler led to reduced gas permeability in porous samples.     

The effect of Mo2C derived carbon pore size on the electrical double-layer characteristics in propylene carbonate-based electrolyte

Carbide-derived carbon (CDC) was synthesised from molybdenum carbide by extracting Mo atoms in a high-temperature chlorine atmosphere. A systematic study of the influence of pore size on the electrical double layer (EDL) performance was carried out with carbons synthesised in the temperature interval of 500-900 °C. Strong effect of chlorination conditions on the pore-size distribution was noticed that gives wide possibilities to vary the pore structure of Mo₂C derived carbons. An average pore size of carbons varied between 1 nm and 2 nm depending on chlorination temperature. The relationships were established between the pore-size distribution and the electrochemical performance of micro/mesoporous carbons. The EDL characteristics of carbon materials in a propylene carbonate solution of triethylmethylammonium tetrafluoroborate were obtained using the cyclic voltammetry at ΔE of 3.8 V and the constant current methods in a 3-electrode test cell. A novel test method was developed to demonstrate the power characteristics of the electrode materials. The results of this study affirmed the great potential of Mo₂C derived carbons, whose EDL capacitance reaches ∼65 F cm⁻³ and 132 F g⁻¹ and the 20-s discharge power density is 2.1 W cm⁻³.     

Preparation of activated carbon derived from Jatropha curcas fruit shell by simple thermo-chemical activation and characterization of their physico-chemical properties

High surface area activated carbons were prepared by simple thermo-chemical activation of Jatropha curcas fruit shell with NaOH as a chemical activating agent. The effects of the preparation variables, which were impregnation ratio (NaOH:char), activation temperature and activation time, on the adsorption capacity of iodine and methylene blue solution were investigated. The activated carbon which had the highest iodine and methylene blue numbers was obtained by these conditions as follows: 4:1 (w/w) NaOH to char ratio, 800 °C activation temperature and 120 min activation time. Characterization of the activated carbon obtained was performed by using scanning electron microscopy (SEM), X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FT-IR) and nitrogen adsorption isotherm as BET. The results present that the activated carbon possesses a large apparent surface area (S_BET = 1873 m²/g) and high total pore volume (1.312 cm³/g) with average pore size diameter of 28.0 Å.     

Production of fibrous activated carbons from natural cellulose (jute, coconut) fibers for water treatment applications

Different fibrous activated carbons were prepared from natural precursors (jute and coconut fibers) by physical and chemical activation. Physical activation consisted of the thermal treatment of raw fibers at 950 °C in an inert atmosphere followed by an activation step with CO₂ at the same temperature. In chemical activation, the raw fibers were impregnated in a solution of phosphoric acid and heated at 900 °C in an inert atmosphere. The characteristics of the fibrous activated carbons were determined in the following terms: elemental analysis, pore characteristics, SEM observation of the porous surface, and surface chemistry. As the objective of this study was the reuse of waste for industrial wastewater treatment, the adsorption properties of the activated carbons were tested towards pollutants representative of industrial effluents: phenol, the dye Acid Red 27 and Cu²⁺ ions. Chemical activation by phosphoric acid seems the most suitable process to produce fibrous activated carbon from cellulose fiber. This method leads to an interesting porosity (S_BET up to 1500 m² g⁻¹), which enables a high adsorption capacity for micropollutants like phenol (reaching 181 mg g⁻¹). Moreover, it produces numerous acidic surface groups, which are involved in the adsorption mechanisms of dyes and metal ions.     

Low-temperature preparation and electrochemical capacitance of WC/carbon composites with high specific surface area

WC/carbon composites (WCCs) with high specific surface area were synthesized by the direct carbonization of a mixture of hydroxylpropyl cellulose, polyvinyl alcohol, K₂WO₄ and K₂CO₃ at 900 °C in flowing N₂. The resultant material was characterized using X-ray diffraction, thermogravimetric analysis, nitrogen sorption and scanning electron microscopy. The electrode performance of this material for use as a capacitor was studied using cyclic voltammetry and galvanostatic charge-discharge measurements. The BET specific surface area of the WCCs varied from 300 to 1000 m²/g depending on the amount of K₂CO₃ added during the preparation. Samples prepared with small amounts of K₂CO₃ contained a large amount of mesoporosity. Electrochemical characterization revealed that WC was slowly oxidized to tungsten oxy-hydroxides, and pseudocapacitance due to the redox reactions of tungsten oxy-hydroxides was superimposed on the double-layer capacitance of the carbon support. Consequently large specific capacitance was observed. Galvanostatic charge-discharge measurements of a WCC (ca. 5 wt% WC) resulted in total specific capacitances as high as 477 and 184 F/g at current densities of 20 and 1000 mA/g, respectively. The long-term cycle stability of WCC was also verified by a 5000 cycle charge-discharge test at 1 A/g.     

Relationship between the nanoporous texture of activated carbons and their capacitance properties in different electrolytes

A series of activated carbons (ACs) with progressively changing nanotextural characteristics was obtained by heat-treatment of a bituminous coal at temperatures ranging from 520 to 1000 °C, and subsequent activation by KOH at 700 °C or 800 °C. As the pre-treatment temperature increases, the total pore volume V_T decreases from 1.28 to 0.30 cm³ g⁻¹, and the BET specific surface area from 3000 to 800 m² g⁻¹. The specific capacitance determined for each series of ACs using symmetric two electrode cells in 6 mol L⁻¹ KOH varies almost linearly with the BET surface area, suggesting that the charge accumulation is controlled primarily by the surface area development. A further analysis of the electrochemical behaviour in different electrolytic media—aqueous and organic—shows that an adequate pore size is more important than a high surface area in order to obtain high values of capacitance. Theoretical values of volumetric capacitance could be evaluated without considering the size of ions, which is always uncertain in solution, and compared with the experimental data as a function of the pore width. The efficiency of pore filling, i.e., of double layer formation, is optimal when the pore size is around 0.7 nm in aqueous media and 0.8 nm in organic electrolyte. A study of the performance of the positive and negative electrodes during the charge/discharge of the capacitor, reveals an additional pseudo-faradaic contribution due to oxygenated functionalities within the working potential window of the negative electrode. This effect is more pronounced for the ACs series obtained at 700 °C, because of their higher oxygen content.     

Carbon adsorbents from waste ion-exchange resins

A series of activated carbons was prepared from different waste commercial ion-exchange resins and studied by means of adsorption, SEM and IR methods. Samples were additionally washed or washed/frozen. This resulted in increases in micro- and mesoporosity in comparison with initial activated carbons. For some samples, the latter treatment gives enhancement of mesoporosity but reduction of microporosity and vice versa comparing with only washed carbons due to different localization of water droplets in mesopores or micropores. Changes in the morphology of chars and activated samples depended on resin composition and history. Relatively high values of porosity (V_p ≈ 0.4 cm³/g) and specific surface area (S_BET ≈ 600 m²/g) show that activated carbons prepared from waste ion-exchange resins can be utilized for different purposes, especially after additional treatment (such as washing, impregnation by certain compounds and subsequent thermal activation).     

Hierarchical porous carbons with controlled micropores and mesopores for supercapacitor electrode materials

Various porous carbons were prepared by CO₂ activation of ordered mesoporous carbons and used as electrode materials for supercapacitor. The structures were characterized by using X-ray diffraction, transmission electron microscopy and nitrogen sorption at 77 K. The effects of CO₂ treatment on their pore structures were discussed. Compared to the pristine mesoporous carbons, the samples subjected to CO₂ treatment exhibited remarkable improvement in textural properties. The electrochemical measurement in 6 M KOH electrolyte showed that CO₂ activation leads to better capacitive performances. The carbon CS15A6, which was obtained after CO₂ treatment for 6 h at 950 °C using CMK-3 as the precursor, showed the best electrochemical behavior with a specific gravimetric capacitance of 223 F/g and volumetric capacitance of 54 F/cm³ at a scan rate of 2 mV/s and 73% retained ratio at 50 mV/s. The good capacitive behavior of CS15A6 may be attributed to the hierarchical pore structure (abundant micropores and interconnected mesopores with the size of 3-4 nm), high surface area (2749 m²/g), large pore volume (2.09 cm³/g), as well as well-balanced microporosity and mesoporosity.