Chemical activation of carbon via a gas atomization method

Abstract

The disclosure relates to methods for forming activated carbon comprising providing a feedstock mixture comprising a carbon feedstock and at least one chemical activating agent, heating the feedstock mixture to at least the fluxing temperature of the feedstock mixture to form a feedstock melt, atomizing the feedstock melt and introducing the atomized feedstock mixture into a reactor, rapidly heating the atomized feedstock to at least the solidification temperature by introducing a hot stream into the reactor, introducing the heated feedstock mixture into a reaction vessel, and holding the heated feedstock mixture in the reaction vessel at a temperature and for a time sufficient to react the carbon feedstock with the at least one chemical activating agent to form activated carbon, wherein rapidly heating the atomized feedstock comprises heating the mixture within a time period sufficient to maintain the feedstock mixture in a substantially solid state throughout the rapid heating stage.