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Article history: Carbon xerogels synthesized with a fixed resorcinol/sodium carbonate molar ratio (R/C)
Received 10 November 2009 were physically activated using CO2. The effect of activation temperature and activation
Accepted 30 April 2010 time on the final properties of the activated carbon xerogels was evaluated. The specific
Available online 8 May 2010 surface area increases from 600 m2 g1 to 2000 m2 g1 and more by increasing the temper-
ature and duration of the activation step. A comparison between physical activation with
CO2 and chemical activation with hydroxides was also performed: it was found that both
processes produce an increase of the micropore volume and specific surface area without
altering the mesoporosity developed during the synthesis. However, chemical activation
can lead to the development of the narrow microporosity mainly whereas, in physical acti-
vation, the widening of the narrow micropores takes place whatever the process
conditions.
2010 Elsevier Ltd. All rights reserved.
have been used: supercritical drying [3–6], freeze-drying [4,7– such treatment on the surface chemistry of carbon gels was
9] and evaporative drying [4,10–14]. The materials obtained by not analyzed. So, the present work deals with the study of
these drying methods are called, after pyrolysis, carbon aero- physical activation of highly mesoporous carbon xerogels
gels, cryogels and xerogels, respectively. with CO2 and the influence of the activation conditions on
Published work on RF carbon gels agree that the synthesis the pore texture and surface chemistry of the activated mate-
and drying steps determine the pore size distribution at the rials. The obtained pore textures were then compared to
mesopore and macropore levels while the microporosity is those obtained by chemical activation of carbon xerogels with
mostly developed during the pyrolysis [2–4,10–14]. These car- hydroxides.
bon materials are composed of microporous interconnected
sphere-like nodules, formed during the gel synthesis via a
microphase separation mechanism induced by polymer
2. Experimental
growth [15,16], the size of which is mainly regulated by the
2.1. Preparation of carbon xerogels
synthesis pH. The development of the micropores takes place
within the nodules during the pyrolysis step, but the mass
Organic aqueous gels were synthesized by polycondensation
loss, and thus the final specific surface area, remains rela-
of resorcinol and formaldehyde in water. Sodium carbonate
tively low and constant [11]. For specific applications, and de-
was used as basification agent. Mechanical and textural prop-
spite their higher cost, carbon xerogels proved interesting as
erties of organic xerogels depend on the synthesis variables:
alternative to classical activated carbons prepared from natu-
(i) the resorcinol/formaldehyde molar ratio (R/F), (ii) the resor-
ral sources: the accurate tailoring of the pore texture led to
cinol/sodium carbonate molar ratio (R/C), and (iii) the dilution
increasing significantly the performance of catalytic [2] and
ratio (D = total solvent/reactants molar ratio) [3,4]. In the pres-
electrocatalytic [17] processes. The same could apply to dy-
ent work, D, R/F and R/C were fixed at 5.7, 0.5 (stoichiometric
namic adsorption. However, to increase the adsorption capac-
ratio), and 1000, respectively, in order to obtain micro-meso-
ity, the relatively low inner surface (600 m2 g1) of carbon
porous carbon xerogel with large mesopores (32–45 nm) [4].
gels should be developed via activation.
160.0 g resorcinol (Vel, 99%) and 0.1540 g sodium carbonate
Basically, one can distinguish two different types of activa-
were first mixed with 303.5 mL deionised water under mag-
tion processes [1,18,19]: chemical activation and physical
netic stirring. After dissolution, 263.1 mL of formaldehyde
activation. In chemical activation, the carbon precursor is
solution (Aldrich, 37 wt.% in water; stabilized by 10–15 wt.%
impregnated with a chemical agent and carbonized. The
methanol) were added to the mixture. So as to avoid too large
chemical is typically a Brönsted acid (H3PO4, by far the most
temperature gradients during gelation and ageing, the solution
used in industry), a Lewis acid (ZnCl2) or a strong base (KOH);
was divided into three equal parts and poured into sealable
note that many other activation agents of these types are
flasks of 250 mL. Gelation and ageing were then performed at
found in the literature, but not used industrially (e.g. NaOH,
70 C in an oven during 72 h. Organic xerogels were obtained
AlCl3, MgCl2, K2CO3, etc.). Then, the raw material is carbonized
by vacuum drying without any sample pre-treatment, i.e.
at temperature ranging from 450 to 900 C). In physical activa-
without solvent exchange prior to drying. The unsealed flasks
tion, the precursor carbonaceous material is usually contacted
were simply kept at 60 C and the pressure was progressively
with CO2, steam or a combination of both during thermal treat-
decreased in two days from 105 Pa to 103 Pa. The samples were
ment. Oxidation by the activating gas significantly increases
then heated to 150 C at 103 Pa during 12 h.
the microporosity of the final product. Although residues
After drying, the gels were pyrolysed at 900 C in
may remain in the final product, chemical activation is
4.1 · 103 mol min1 flowing nitrogen in a horizontal tubular
preferred over physical activation owing to the lower tempera-
furnace. The heating program included the following sequen-
tures and shorter time needed for activating the material.
tial steps [11]: (i) ramp at 1.7 C/min to 150 C and hold for
In previous work [20,21], carbon xerogels with high surface
15 min; (ii) ramp at 5 C/min to 400 C and hold for 60 min;
area (up to 1800 m2 g1) were obtained by chemical activation
(iii) ramp at 5 C/min to 900 C and hold for 120 min; and (iv)
with alkali hydroxides. The method proved efficient for
cool slowly to room temperature. Note that the pyrolysis pro-
increasing the specific surface area without altering the
cedure can be simplified: tests have shown that the process
meso-macropore texture, and it was concluded that surface
can be reduced to one heating ramp and one temperature
development occurs through the appearance of new microp-
step without damaging the final pore texture.
ores, formed within the carbon nodules by the alkali. How-
ever, the pore texture development may differ from one
activation process to another [18] and, to our knowledge, no 2.2. Activation of carbon xerogels
study comparing the activation of carbon xerogels using var-
ious processes was previously published. In fact, few data The pyrolyzed samples were crushed and sieved between 0.5
concerning the activation of carbon gels with CO2 are avail- and 1.0 mm. Note that crushing carbon xerogels does not
able in the literature. In 2000, Lin and Ritter [10] activated a modify their pore texture. Indeed, gas adsorption performed
mainly microporous carbon xerogel with CO2 under very spe- on both monoliths and powders with granulometry down to
cific conditions. In 2006, Fairén-Jiménez et al. [22] reported the 30–50 lm lead to the same result [2,17]: after crushing, one ob-
activation of a carbon aerogel prepared with paratoluene sul- tains the so-called ‘‘micromonoliths’’ that retain the pore tex-
fonic acid as pH modifier. However, the effect of CO2 activa- ture of the pristine non-crushed material. The samples were
tion strongly depends on the pristine carbon properties, crushed and sieved for two reasons: (i) to avoid CO2 concen-
such as its structure and composition [23], and the effect of tration gradients within the particles that could lead to
CARBON 4 8 ( 20 1 0 ) 3 1 5 7–31 6 8 3159
inhomogeneous activation (the size of the carbon particles hampered by very slow diffusion, and several weeks may be
influences the development and the characteristics of the required to obtain accurate adsorption isotherms [24]. So,
porosity [23]) and (ii) because their final use (adsorption in li- the use of carbon dioxide adsorption at 0 C has been estab-
quid media) required small particles of homogeneous size. lished as an effective procedure for appropriate textural char-
In order to study the influence of the activation tempera- acterization of the narrow micropores [24,25]. In this case,
ture, Tact, and activation time, tact, i.e. the duration of the acti- the higher adsorption temperature (0 C instead of 196 C)
vation step, the samples were then activated in the horizontal results in a larger kinetic energy of the CO2 molecules,
tubular furnace used for pyrolysis. The unactivated carbon which are thus able to reach the narrow microporosity de-
xerogel was heated at 5 C/min from room temperature to spite slightly bigger in size than the molecules of N2. The
the chosen activation temperature under a constant nitrogen combination of N2 and CO2 adsorption provides complemen-
flow (4.1 · 103 mol min1). Once the temperature was tary and relevant information about the whole micropore
reached, the nitrogen flow was replaced by a constant flow range.
of pure CO2 (4.1 · 103 mol min1) for activation. Two series Carbon dioxide adsorption isotherms of samples were
of activated carbon xerogels were obtained by using two dif- thus determined at 0 C in a TriStar 3000 from Micromeritics.
ferent activation temperatures, Tact, equal to 800 C and The Dubinin–Radushkevich method [26] was applied to the
900 C. The temperature and gas flow were left constant carbon dioxide adsorption isotherms in order to obtain the
and, within a series, the activation time, tact, was modified. narrow micropore volume, VDUB-CO2 , and the carbon-CO2 inter-
After activation with CO2, the nitrogen flow was restored, action energy, E0-CO2 . The corresponding micropore specific
helping cooling down the samples in inert atmosphere. For surface area, SCO2 , was evaluated from:
the samples activated at 800 C, tact was chosen equal to 4,
16 and 24 h. In the case of samples activated at 900 C, tact VDUB-CO2
SCO2 ¼ 2 ð1Þ
of 4, 8 and 16 h were selected. L
2.3. Sample designation where SCO2 and VDUB-CO2 are expressed in m2 g1 and m3 g1,
respectively, and L (m) is the micropore size calculated either
The samples obtained in this work are labelled as follows. The from Stoeckli and Ballerini [27] for E0-CO2 values between 20
first two letters refer to the type of precursor: CX for carbon and 42 kJ/mol, or from the Dubinin equation for lower values
xerogels. These letters are followed by the activation temper- of E0-CO2 [25]. Finally, the skeletal density of the carbons, qs,
ature. The last number refers to the activation time. For was obtained by helium pycnometry using a pycnometer
example, sample CX-900-4 was activated with CO2 at 900 C Micromeritics Accupyc 1330. The bulk density, qbulk, was cal-
during 4 h. culated by:
CARBON
adsorption data; VDUB-CO2 : micropore volume determined from CO2 adsorption by the Dubinin–Radushkevich equation; E0-CO2 : CO2–carbon interaction energy calculated by the Dubinin–Radushkevich
equation; L: average micropore size determined from Stoeckli or Dubinin equation; SCO2 : specific surface area determined from CO2 adsorption, calculated from VDUB-CO2 and L; qs: skeletal density
measured by helium pycnometry; qbulk: bulk density obtained from Vv and qs.
a
Not pertinent.
4 8 ( 20 1 0 ) 3 1 5 7–31 6 8
b
Not measured.
100
0.5
50
0
0
0
0
20
Δm/m (%)
0.015
p /p 0
40 60
0.03
80
3161
3162 CARBON 4 8 ( 2 0 1 0 ) 3 1 5 7 –3 1 6 8
(samples CX-900-8 and CX-900-16) while VDUB-N2 increases and (ii) the widening of these narrow micropores, both phe-
continuously up to 0.98 cm3 g1 (CX-900-16). This behavior is nomena occurring during the whole activation process [25].
typical, and was observed for other activated carbons derived Helium pycnometry was used to measure the skeletal den-
from various precursors [25,34]: (i) for low burn-off degree, the sity, qs, of the carbons, and the bulk density, qbulk, was calcu-
activation process develops the narrow microporosity inac- lated according to Eq. (2). Globally, one can observe a slight
cessible to nitrogen; (ii) from a sufficiently high burn-off de- increase of the skeletal density with activation (Table 1): from
gree, the narrow micropore volume does not increase 1.89 g cm3 (CX) to 2.04 g cm3 (CX-800-24) for the CX-800 ser-
anymore (and eventually decreases at high Dm/m) while the ies, and up to 2.18 g cm3 for the CX-900 series. This could re-
micropore volume detected by nitrogen adsorption still in- flect the opening of closed microporosity, the skeletal density
creases. This indicates that the increase of total micropore of graphite being close to 2.25 g cm3. The bulk density, qbulk,
volume occurs through (i) the creation of narrow micropores decreases when the burn-off degree increases: for example, in
the CX-900 series, qbulk decreases from 0.46 g cm3 (CX-900-4:
Dm/m = 18%) to 0.31 g cm3 (CX-900-16: Dm/m = 60%). This re-
15 flects both the development of microporosity for all the acti-
vated samples, and the increase of mesopore volume
observed at very high burn-off degree (CX-900-16).
a 0.60 b 0.08
n CO2 (µmol g-1 s-1) , relative units
n CO (µmol g-1 s-1) , relative units
0.30 0.04
0.00 0.00
0 500 1000 0 500 1000
T (ºC) T (ºC)
Fig. 5 – CO (a) and CO2 (b) desorption profiles for carbon xerogels synthesised using R/C = 1000, non-activated and physically
activated with carbon dioxide at 800 C during 24 h; and at 900 C during 4, 8 and 16 h: (·) CX, (D) CX-800-24, (j) CX-900-4, ()
CX-900-8, (d) CX-900-16. For clarity, the curves are shifted upwards, and the corresponding ground levels are indicated by
dotted horizontals.
CARBON 4 8 ( 20 1 0 ) 3 1 5 7–31 6 8 3163
a 0.06 b 2500
2000
0.03
1000
500
0 0
0 12 24 0 12 24
t act (h) t act (h)
Fig. 6 – (a) Average specific gasification rate for activated xerogels as a function of activation time, (b) specific surface area for
activated xerogels as a function of activation time (.) CX-900 series, (5) CX-800 series.
The presence of peaks also allows determining the nature prepared at fixed activation time. One can observe (Fig. 6a)
of the oxygen groups present on the carbon surface. The oxy- that, at constant activation temperature, the average specific
gen groups decompose with the evolution of CO (ethers, gasification rate, rs , decreases slightly with activation time:
anhydrides, phenols, carbonyls, quinones) or CO2 (carboxylic indeed, rs decreases from 0.010 to 0.008 h1 for the series set
acids, anhydrides, lactones) [29]. However, since the amounts at 800 C when increasing tact from 4 to 16 h while, for the
desorbed are very small, it is not easy to attribute the peaks CX-900 series, rs decreases from 0.045 to 0.038 h1 for the
observed to distinct oxygen surface groups and quantify their same tact range. This could be due to the fact that, at the
relative proportions. A qualitative analysis remains possible. beginning of the gasification, some carbon surface atoms
The CO desorption observed below 500 C for CX and are more prone to elimination by gasification with CO2; with
CX-800-24 (Fig. 5a) could be attributed to some carboxylic time, these preferential sites disappear, and gasification pro-
anhydrides groups. Phenol and ether groups lead to CO ceeds with the elimination of more stable carbon atoms. In
desorption around 600–700 C while detection of CO at tem- addition, comparison of CX-800 and CX-900 series shows that
perature higher than 700 C could reflect the elimination of rs globally increases with the temperature (Fig. 6a), which is in
carbonyl and quinone groups. The peak observed near agreement with previous studies [35].
800 C for all samples can be attributed to the presence of car- The specific surface area, SBET, develops with activation
bonyl and quinone groups; the intensity of this peak is almost time (Fig. 6b and Table 1). The development of microporosity,
twice higher for CX-800-24 than for the CX-900 series. Con- which can be interpreted in terms of increase of specific sur-
cerning CO2 desorption, peaks located between 200 and face area, SBET, is directly related to the activation tempera-
400 C indicate the presence of carboxylic acids, and maybe ture (which increases the average specific gasification rate)
carboxylic anhydrides, which would match the desorption and activation time. As shown in Fig. 6b, SBET increases quite
of CO in the same temperature range. The small shoulder ob- linearly with tact. However, the average specific gasification
served for all the samples at 500 C could also indicate the rate is about three times higher at 900 C than at 800 C, as
presence of carboxylic anhydrides. For all samples activated, also shown by the slope difference in the SBET vs. tact plot of
CO2 desorption is also observed between 500 and 800 C, indi- CX-800 and CX-900 series.
cating maybe the presence of lactone groups. As a general Many studies report specific surface area development
observation, the nature and amounts of oxygen surface using chemical activation or physical activation [1,18,19,36–
groups do not change drastically with the activation condi- 43]. Since carbon xerogels were previously activated with
tions: all the obtained CO and CO2 desorption spectra are sim- hydroxides (NaOH and KOH) [20,21], the present study allows
ilar, and the amounts desorbed are quite low. for comparing the two procedures. Fig. 7 shows the specific
surface area, SBET, for xerogels chemically activated with
4. Discussion NaOH and KOH as a function of the activation agent/carbon
precursor mass ratio (A/P), and Fig. 8 shows the CO2 adsorp-
In physical activation of carbon xerogels, the effect of the tion isotherms of two carbon xerogels, activated with KOH
activation time, at constant activation temperature, on the at various A/P values (A/P = 2, sample KOH-2 and A/P = 4,
porosity development can be studied through a comparison sample KOH-4). It was observed from nitrogen adsorption iso-
of the sample series activated either at 800 C or at 900 C. therms that chemical activation produces an increase in
In the same way, the effect of temperature can be determined micropore volume, VDUB-N2 , and thus specific surface area,
through a comparison between CX-800 and CX-900 samples SBET; however, the activation modifies neither the 3D structure
3164 CARBON 4 8 ( 2 0 1 0 ) 3 1 5 7 –3 1 6 8
a 1.00 b 0.16
n CO2 (µmol g-1 s-1) , relative units
n CO (µmol g-1 s-1) , relative units
0.50 0.08
0.00 0.00
0 500 1000 0 500 1000
T (ºC) T (ºC)
Fig. 9 – CO (a) and CO2 (b) desorption profiles for carbon xerogels synthesised using R/C = 1000, non-activated, physically
activated with carbon dioxide at 800 C during 24 h, physically activated with carbon dioxide at 900 C during 16 h; and
chemically activated with KOH: (·) CX, (D) CX-800-24, (d) CX-900-16, (+) sample activated with KOH, A/P = 4 (data from Ref.
[20]). For clarity, the curves are shifted upwards, and the corresponding ground levels are indicated by dotted horizontals.
3166 CARBON 4 8 ( 2 0 1 0 ) 3 1 5 7 –3 1 6 8
of high quantities of phenol, ether, quinone and/or carbonyls cesses. Comparison of micropore volumes obtained either by
groups. The large CO2 peak observed for KOH-4 at 250 C is N2 or CO2 adsorption shows that, during chemical activation
probably due to carboxylic groups, the development of which with hydroxides, the narrow microporosity first develops via
is clearly higher in the case of chemical activation. Again, dur- the appearance of new narrow micropores; at high A/P ratio,
ing TPD experiments, most of the oxygenated surface groups enlargement of micropores, which could occur via the breaking
are eliminated at temperatures lower than that of the activa- of walls separating individual micropores, is detected. In the
tion treatment (750 C [20,21]). The difference observed be- case of physical activation, the enlargement of narrow microp-
tween these two activation procedures could be due to the ores starts immediately, whatever the activation conditions,
difference of re-oxidation mechanisms. Indeed, potassium which leads to the development of microporosity with a wider
or sodium introduced as chemical reagents remain in the car- size range. So, should narrow micropores be required in the fi-
bonaceous material until re-exposure to air, and could there- nal activated carbon xerogels, the use of chemical activation
fore induce consequent surface re-oxidation. On the with relatively low A/P ratio is recommended. If extremely pure
contrary, in physical activation, the carbon surface is treated materials are necessary, physical activation would better be
thermally and the oxygen-containing surface groups are re- used. Concerning the mesopores and macropores, the texture
moved. So, re-oxidation can only be induced by very reactive of carbon xerogels is preserved as long as the degree of carbon
carbon sites left at the surface that can react with the oxygen removal is not too high (i.e. relatively low burn-off degree in the
when they are exposed to the room-temperature air. Much case of CO2 activation, and A/P ratio < 4 in the case of chemical
likely, the amount of these active sites is rather low, which ex- activation with KOH). However, (i) in the case of activation with
plains the low amounts of oxygen surface groups detected, CO2, one observes an increase of the mesopore volume at high
while oxidation induced by potassium or sodium is easier, burn-off degree and (ii) chemical activation with KOH may lead
leading to increasing the surface oxidation. to meso/macropore enlargement at high A/P ratio [20]. From re-
sults presented in this study and in previous work [20,21], it is
5. Conclusions not possible to conclude about the mechanisms of meso/mac-
ropore development during the activation of carbon xerogels;
The physical activation of carbon xerogels using carbon diox- however, the mechanism is much probably quite different from
ide allows the production of materials with a well developed one activation technique to another. Indeed, whereas the for-
microporosity without any alteration of the mesoporosity mation of micro, meso, and macropores in a physical activation
formed during the synthesis. Increasing the activation temper- process is usually the consequence of carbon burn-off and pro-
ature from 800 C to 900 C leads to increasing the gasification gressive pore widening, this is not necessarily the case for
rate from 0.01 to 0.04 h1; moreover, the developed surface chemical activation processes, in which pore development
depends linearly on the burn-off degree. Thus, it is possible can be the result of very complex reaction schemes [46].
to control the surface development easily. However, the activa- Both activation types could be directly subsequent to pyro-
tion time remains very long to reach very high specific surface lysis in a continuous process. However, it was demonstrated
areas, even at 900 C (10 h for SBET 1500 m2 g1); physical previously [20] that coupling with pyrolysis is not possible in
activation should then be conducted at higher temperature, the case of chemical activation with hydroxides, because
which is a major drawback of the process from the point of view the direct activation of organic gels leads to the destruction
of costs. of the initial meso-macropore texture. The effect of direct
Physical activation of carbon xerogels was compared to CO2 activation of organic resorcinol–formaldehyde gels on
chemical activation using hydroxides. Globally, both pro- the textural properties of the final carbon should be the scope
cesses lead to the development of the microporosity without, of further works aiming at the optimization of the physical
to some extent, damaging the meso-macroporosity obtained activation process.
via sol–gel chemistry. Chemical activation has several advan-
tages: (i) as in the case of many other precursors, the temper-
ature required is lower, which is why this process is generally Acknowledgements
preferred, (ii) the time required to produce equivalent surface
development is shorter and (iii) the micropore development of N.J. and C.P. are postdoctoral researchers of the F.R.S.-FNRS
carbon xerogels is more uniform, the enlargement of narrow (Belgium). A.L. is research associate of the F.R.S.-FNRS (Bel-
micropores taking place at high chemical agent concentration gium). The Belgian authors thank the Fonds de Recherche
only. However, physical activation (i) does not require any cor- Fondamentale Collective, the Ministère de la Région Wallonne
rosive agents, (ii) leads to activated carbon xerogels with very and the Interuniversity Attraction Pole (IAP-P6/17) for their
low ash content without requiring a washing treatment and financial support.
(iii) leaves a surface containing much lower concentration of
oxygen surface groups than in the case of the xerogels ob-
tained by chemical activation with hydroxides. Since con- R E F E R E N C E S
trolled oxidation remains possible afterwards [29,30],
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