Preparation and characterization of activated carbon foam from phenolic resin

Activated carbon foam was successfully prepared from phenolic resin synthesized with phenol and formaldehyde under alkali condition. The influence of process variables, such as steam rate, carbonization temperature, carbonization time, activation temperature and activation time on the adsorption capacities of the activated carbon foam was studied. Under the optimum experimental conditions, the activated carbon foam with a specific surface area 727.62 m2/g was obtained. Moreover, the iodine value and carbon tetrachloride value of the activated carbon foam was 1050.28 mg/g and 401.37 mg/g, respectively. The pore size of the activated carbon foam was in the range of 3.5–5 nm which was determined through the N2 adsorption test. In addition, the yield of the activated carbon foam was 36.24%. The result of scanning electron microscopy (SEM) showed that the activated carbon foam became honeycomb structure, and its pore wall was thinner and smoother compared to the unactivated carbon foam.