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Activated Charcoal Preparation, Characterization and
Activated Charcoal Preparation, Characterization and
Activated Charcoal Preparation, Characterization and
Introduction
Adsorption is a widely used as an effective physical Applications of Activated Carbon (AC)
method of separation in order to elimination or lowering Applications of AC are enormous. Its important use is for
the concentration of wide range of dissolved pollutants gasoline vapor emission control canisters in automobile.
(organics, inorganic) in an effluent. It is big news that AC can act as a filter material in air cleaning filters for
activated carbon (AC) is a well known adsorbent that can removal of gases and vapors in the industrial
be used efficiently for removal of a broad spectrum of environment. Especially impregnated grades are used in
pollutants from air, soil and liquids. Adsorbents are cigarette filters to adsorb some of the harmful
usually porous solids, and adsorption occurs mainly on components of tobacco, and as the catalyst or carrier of
the pore walls inside particles. Examples are activated catalytically active substances. Heavy metal ions such as
carbon (adsorbs mainly organics), silicagel and activated mercury, lead and cadmium in drinking waters are very
alumina (adsorb moisture), zeolites and molecular sieves dangerous even in trace amount, and adsorption method
and synthetic resins. Among them, AC is more efficient for removing these ions can be essential for water and
adsorbent for elimination of many pollutants (organic, waste water contaminated by heavy poisonous metal
inorganic, and biological) of concern in water and ions. For example lead, cadmium, mercuric ions all are
wastewater treatment. very toxic and carcinogenic. Lead is also a cumulative
In the recent years, it has been increasingly used for the metabolic poison, acting as a mutagen when adsorbed in
preventation of environmental pollution and antipollution excessive amounts. These ions can not be removed from
laws have increased the sales of AC for control of air and water with classic physical or chemical treatments
water pollution. AC is a broad-spectrum agent that completely. Activated carbon can be used for removal of
effectively removes toxic and bio-refractive substances poisonous heavy metal ions from aqueous solutions.
such as insecticides, herbicides, chlorinated Adsorption in this case is due to the surface complex
hydrocarbons, heavy metal ions, and phenols, typically formation between the metal ions and the acidic surface
present in many water supplies [1-10]. AC in fact is a function group of AC. Adsorption is due to the surface
microcrystalline, non-graphitic form of carbon with complex formation between the metal ions and the acidic
porous structure that has been processed to develop its surface function group of AC. The removal efficiency is
internal porosity. AC has a high degree of porosity, an influenced by various factors, such as solution
extensive surface area, and a high degree of surface concentration, solution pH, ionic strength, nature of
reactivity. Its large specific surface area of (500 - 2000 adsorbate, adsorbent modification procedure, Physical
m2/g) is in fact the most important physical property of properties (surface area, porosity), and the chemical
AC which allows the physical adsorption of gases or nature of AC [11-20].
vapors and dissolved or dispersed substances from Simple metal ions are not usually good adsorbates
liquids. It has large number of very fine pores because of their good solvation in aqueous solutions. The
(microspores) gives the AC a large inner surface, which better solvation may lead to poor absorbability of metal
is the basis of its remarkable adsorption properties. ions. However it is possible to increase the rate of
Consequently, they are effective adsorbents for many adsorption with impregnation of AC with suitable
pollutant compounds (organic, inorganic, microbial and chelating agents or modification of the adsorbents. Since
biological) of concern in water and wastewater treatment. AC is a hydrophobic adsorbent, so it seems to be not a
R. Ansari et al /Int.J. ChemTech Res.2009,1(4) 860
good candidate for adsorption of simple inorganic ions Preparation of Active Carbon
from polar aqueous solution; however, it is possible to Any carboneous materials (animal, plant, or mineral
improve the rate of adsorption of heavy metal ions by origin) with high concentration of carbon can be simply
pretreatment of AC with some suitable chemical changed into activated carbon (using both chemical or
reagents. Sorption improvement is based on simple gas activation methods), The most common raw materials
chemical reactions that are common in chemistry such as are wood, charcoal, nut shells, fruit pits, brown and
acid-base or neutralization, complex formation, redox, bituminous coals, lignite, peat, bone and paper mill waste
precipitation, hydrolysis and catalytic reactions. For (lignin), synthetic polymers like PVC, are used for
example if AC is impregnated by molecule, ions and manufacturing of activated carbon. Activated carbon
chelating agents that can combine with transition metal obtained from hard wood is preferable for adsorption
ions to form precipitation, complex or chelates, they can because charcoal obtained from soft wood, such as
improve adsorption of metal cations significantly. The pinewood, is very unstable and readily crumbles. It has
adsorption of mercury ion is also increased in acidic been reported that the best grades of AC are obtained
solutions and also when treated with surface sulphurized from the coconut shell and apricot pits. Activated carbons
AC. AC impregnated with organic compounds with are commonly prepared by two basic processes: (i)
active groups like –SH, -NH can provide more effective Physical or gas activation method, and (ii) Chemical
adsorption and elimination of heavy metals from the activation. The choice of activation method is also
effluents. depending upon the starting material and whether a low
As a general rule of thumb is that similar materials tend or high density, powdered or granular carbon is desired.
to associate, AC generally, most effectively adsorbs large In gas activation method the raw material with less than
and least soluble organic molecules from aqueous 25% moisture, is carbonized first at 400 - 500 oC to
solutions. The smaller organic molecules can also be eliminate the bulk of the volatile matter and then the
adsorbed if they fit into the smaller pores. Activated carbon is subjected to oxidizing gases usually carbon
carbon has many applications for the purification of dioxide or steam at 800-1000 oC or and with air at law
products of the chemical, food and pharmaceutical temperature, for selective oxidation [20-24]. The
industries. It is widely used to remove color and other oxidation is preceded usually by a primary carbonization
impurities such as those causing foaming or retarding of raw material. The pyrolysis of wood starts at
crystallization from sugar, in electroplating bath to temperature about 225 oC.
removing organic impurities and to recover valuable Carbon is oxidized by atmospheric oxygen is oxidized to
substances from gas and liquid streams. Highly colored CO2, so the air should be excluded or very controlled
waste streams such as result from dying operations can be during carbonizing and activating. Steam and carbon
cleaned-up by activated carbon. Its first use came into dioxide act as mild oxidizing agents at 800-1000 oC as
prominence through its use as an adsorbent for certain follow:
poisonous gases in gas masks in World War 1. Cx(H2O)y®C (s) + y H2O Carbonization
The major use of activated carbon is in solution
purification and for the removal of taste, color, odors and C (s)+ 2H2O®CO2 + 2 H2 Steam activation (DH =
other objectionable impurities from liquids, water +75 KJ)
supplies and vegetable and animal oils. In the recent C(s)+CO2®2 CO Activation by CO2 ( DH = +159 KJ)
years, it has been increasingly used for the preventation
of environmental pollution and antipollution laws have The activation of charcoal consists in thermal treatment
increased the sales of AC for control of air and water at high temperatures (800-1000oC), as a result, these
pollution. The amount of material that can be adsorbed incomplete combustion products burn up and volatilize.
by AC is surprisingly large, amounting frequently to form Then the surface of the carbon is tremendously increased
a quarter to an equal weight of such vapors as gasoline, by the removal of hydrocarbon or tars (Figure 1).
benzene, and carbon tetrachloride. It has been reported
that coal carbons are 99% effective for dye removal and
could accept dye loadings as 0.40 kg dye per kg of AC.
In order to make it economical, fixed bed systems
containing granular carbon could be used in tertiary
treatment of wastewater. Although there are many
chemical, physical, and biological methods of treating
water contaminated with industrial and municipal wastes
to produce safe and palatable drinking water, none of Figure 1: Gradual activation process of carbon
them have the potential of AC treatment. during thermal treatment
R. Ansari et al /Int.J. ChemTech Res.2009,1(4) 861
The Poor absorbability of normal charcoal can be due to achieved by washing with organic solvents, mineral
its small and very limited surface area due to the filling acids, caustic soda, steam, or dry heat under vacuum but
its pores largely with resins and products of incomplete powdered form is very difficult. High-density starting
combustion which are formed during preparation of materials such as coconut shells are used for preparation
charcoal. Activation process sweeps the tarry materials, of AC for gas phase applications.
opens the pores, develop porosity, and increase surface The relative capacity of different carbons is best assessed
area significantly. Gas-phase, vapor-adsorbent carbons by trial upon the water to be treated. The pore structure
are granule form usually prepared from physical or gas limits the size of molecules that can be adsorbed, and the
activation method. These carbons are hard granules, surface area limit the amount of material that can be
relatively dust-free pellets having pores diameter less adsorbed, assuming suitable molecular size. For
than 3 nm. These carbons are made from hard, dense screening purposes many manufacturers test their
starting materials such as nutshells and fruit pits. These products upon standard solutions to yield iodine,
are carbonized first, and then crushed to a powder, form molasses, phenol and methylene blue numbers. The most
it into granule with a tar or pitch binder then activate with commonly applied gas adsorption tests are carbon
steam or flue gas at 800-1000 oC. In chemical method, tetrachloride and benzene activity tests. Concentration of
both carbonization and activation processes are carried organic contaminants can affect the adsorption process. A
out simultaneously. The raw material generally used is given AC filter may be more effective than another type
sawdust or peat, which is mixed with the chemical agent of AC filter at low contaminant concentrations, but may
in proper ratio, dried, and carbonized at temperatures up be less effective than the other filter at high
to 800 oC in the absence of the air (under vacuum or inert concentrations. The filter manufacturer should be
gas), after carbonization has been completed, the residual consulted to determine how the filter will perform for
impregnating agent is removed by leaching with water. specific chemicals at different levels of contamination.
Inorganic chemicals such as zinc chloride, phosphoric The process of adsorption is also influenced by the length
acid and alkali metal hydroxide to degrade or dehydrate of time that the AC is in contact with the contaminant in
the organic molecules during carbonization that prevent the water and amount of adsorbent.
deposition of hydrocarbon on the carbon surface. Other important factors that determine the adsorption
Calcination or carbonization is carried out in a furnace properties of AC are the pore size distribution and the
specially designed (internally heated rotary kilns are most type of functional groups on the surface. All activated
commonly used) for the purpose to permit removal of the carbons posses not only carbon, but also small amounts
entire adsorbed hydrocarbon and some of the carbon, so of chemically bonded oxygen and hydrogen in the form
increase the surface area. of various functional groups that usually gives acidic
A highly active decolorizing carbon is obtained by a character to solid carbon, plus mineral matters which is
rapid process in high yield at a relatively low reaction usually indicated as ash or residue after ignition. The ash
temperature (600-700 oC) with zinc chloride activation. (inorganic) has catalytic effects during carbonization,
However, the cost of recovery of the activating chemicals activation, and adsorption processes. The ash content, ash
is high. In the case of sawdust, the activating agent most composition, nature of the surface chemistry and pH of
commonly used is H3PO4 (350-500 oC). Because of the carbon are the most important chemical properties of
pollution problem of ZnCl 2, this method has become activated carbon. The presence of H, O, and other atoms
most popular recently. Some raw materials such as bones in activated carbon has important effects on adsorption.
contain inorganic salts that impart some degree of For example, for removing polar organic compounds
activity to the carbon when is simply heated or heated in from water, the carbons associated with polar oxygen
an inert atmosphere. Commercial grades of activated surface structures should preferable, where oxygen-free
carbon are assignated as either gas-phase or liquid phase carbons should be used for removing nonpolar organic
adsorbents. Liquid-phase carbons are generally in the compounds. Similarly, when the organic compounds
form of powdered or granular is characterized as having have a large size, carbons with a greater percentage of
larger pores (3 nm in diameter and larger) because of large pores should be used.
need for rapid diffusion in the liquid decolorizing Although AC has been mostly recognized for its
activated carbon are usually employed as powdered. application for removal of organic pollutants from polar
Powdered activated carbon has an extremely high ratio of solutions like water, but we have found in our Lab.
area to volume, and since adsorption is a surface Research that it can be used for sorption of many
phenomenon, so this increases its effectiveness, but also inorganics efficiently. Most of these sorptions are very
makes it slow to settle and difficult to remove once pH dependent. Chromium hexavalent ion (a well known
added. Many decolorizing carbons are prepared by carcinogenic agent) can be adsorbed by AC only under
chemical activation. acidic conditions and under alkaline conditions (pH > 8)
Decolorizing carbons are coal and lignite based granules, not any adsorption of these substances was observed [5].
or light, fluffy powders derive from low density starting
materials such as sawdust or peat. Approximately 60% of Mechanism of adsorption
the activated carbon manufactured for liquid phase When a gas or vapor is brought into contact with a solid,
applications is used in powdered form. Regeneration of part of it is taken up by the solid. The molecules
the used granule form of activated carbons can be disappear from the gas or solution either enter the inside
R. Ansari et al /Int.J. ChemTech Res.2009,1(4) 862
of the solid (termed absorption), or remain on the outside and packed or expanded) or downflow mode. In
attached to the surface (termed adsorption). When the downflow systems, the adsorbent can serve for
phenomena occur simultaneously, the process is termed adsorption and for filtration of suspended solids (make
sorption. The solid that takes up the molecule is called adsorption less efficient). Adsorption columns behave in
adsorbent, and the gas, vapor or solute taken up on the much the same way as ion exchange columns during
surface is called adsorbate. Many organic and inorganic operation. Most commercial applications use AC in a
contaminants are removed from either gaseous or liquid fixed bed. Fluid passes down through the bed and
solutions by adsorption on the very porous medium (solid components adsorb onto the solid. Continuous –flow
phase) with large internal surfaces. Adsorption is a adsorption systems are capable of treating large volume
reversible reaction; at a given solute concentration. of wastewater and are widely used for both municipal and
Adsorbates can attach themselves onto surfaces in two industrial applications.
ways. In physisorption (physical adsorption), there is a The use of upflow or down flow columns in series are
weak van der waals attraction of the adsorbates to the used to optimize adsorbent usage and operating costs.
surface. During the process of physisorption, the The feasibility of using adsorption for a given waste
chemical identity of the adsorbate remains intact. treatment application must be determined by laboratory
Physisorption is a spontaneous process (∆G < 0), since and pilot plant tests. In almost all cases the initial tests
∆S is negative, so ∆H be exothermic. In chemisorption consist of laboratory scale, constant temperature
(chemical adsorption), the adsorbates stick to the solid by (preferably at the value anticipated for the wastewater
the formation of a chemical bond with the surface. This during treatment), constant pH (should match with the
interaction is much stronger than physisorption and in value anticipated for the actual wastewater), batch
general, chemisorption has more stringent requirements adsorption studies.
for the compatibility of adsorbate and surface than
physisorption [25-28]. Adsorption isotherms
The steps of adsorption can be summarized: solute The performance of an adsorbent for adsorption of a
diffuses near the solid surface, diffuses into the pores of specific adsorbate and also valuable information (e.g. the
particle, then to the pore wall and adsorbs to the pore theoretical capacity of the sorbent exhaustion) can be
wall surface. Adsorption of dissolved contaminants is a obtained from plotting adsorption isotherm. The
complex phenomenon caused by several mechanisms, relationship between the concentration of chemical
including London- van der Waals forces, Coulomb adsorbed (S) and the concentration remaining in the
forces, hydrogen bonding, ligand exchange, solution C at equilibrium is referred as the adsorption
chemisorption, dipole- dipole forces, and hydrophobic isotherm because the experiments are performed at
forces. For example, hydrocarbons most commonly constant temperature. Adsorption isotherms generally
exhibit adsorption through the process of hydrophobic exhibit one of three characteristic shapes, depending on
bonding. Thus adsorbents are characterized first by the sorption mechanism. These isotherms are referred as
surface properties such as surface area, pore size the linear isotherm, the Freundlich isotherm and the
distribution of micropores and polarity (hydrophilicity, Langmuir isotherm.
hydrophobicity). The gas adsorption itself, however, can Adsorption isotherm will describe the equilibrium
be used to determine the accessible surface area of most distribution of solute between the solid and liquid phases.
adsorbents. When the surfaces of the sorbent matrix are The results are usually expressed as a plot of the
less polar than the water molecule, as is generally the concentration of chemical adsorbed (mg g-1) versus the
case, there is a strong tendency for the nonpolar concentration remaining in solution (mg L-1). Adsorption
contaminant molecules (e.g. oil or hydrocarbons) to isotherms are generated by contacting a fixed quantity of
partition from the solution and adsorb to the adsorbent. contamination (e.g. 100 mL) with different amounts of
This phenomenon referred as hydrophobic bonding, is a adsorbent (e.g. 5 flasks) for a fixed length of time in
very important factor controlling the fate of many organic order to remove impurities. Three types of equilibrium-
pollutants in water and soils. A large specific surface controlled sorption isotherms are considered in transport
area is preferable for providing large adsorption capacity. models: linear, Freundlich and Langmuir [26, 29-32].
Especially materials such as zeolite and carbon molecular The linear sorption isotherm assumes that the sorbed
sieves can be specifically engineered with precise pore concentration is directly proportional to the dissolved
size distribution tuned for a particular separation. concentration. Freundlich equation is one of the most
Adsorption processes can be operated on either a batch or popular empirical equations which is used to express the
continuous- flow basis. In batch processes the sorbent mathematic relationship between the quantity of impurity
and wastewater are mixed together in a suitable reaction remaining in solution versus the quantity adsorbed:
vessel until the concentration of solute has been reduced
to the desired level. Separation of the spent sorbent X/m= KCe 1/n (1)
leaves an effluent suitable for discharge. The sorbent can
be regenerated and reused. Most continuous– flow Where X/m is the amount of impurity (mg) adsorbed per
adsorption systems are operated as single column or gram of the adsorbent, m is the mass of adsorbent (g),
multiple fix-bed adsorption columns in series. x/m value represents the adsorptive capacity of an
Furthermore, they may be operated in either the upflow adsorbent. Ce stands for equilibrium concentration or final
R. Ansari et al /Int.J. ChemTech Res.2009,1(4) 863
Ce / qe = 1/Qo ´ b + Ce / Qo (4)
R. Ansari et al /Int.J. ChemTech Res.2009,1(4) 864
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