Generation of carbon materials

Abstract

Disclosed herein are carbon materials, including porous carbon materials comprising pores of various sizes, optionally mixtures of micropores, mesopores, and / or macropores. Also disclosed herein are methods for obtaining carbon materials, including porous carbon materials comprising two or more of micropores, mesopores, and macropores. In addition, also disclosed is the use of carbon materials, including porous carbon materials comprising two or more of: micropores, mesopores, and macropores, in particular those obtained from the methods described herein.

Description

"GENERATION OF CARBON MATERIALS"CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority from Australian Provisional Patent Application No 2024900757 filed on 21 March 2024, the contents of which are incorporated herein by reference in their entirety.TECHNICAL FIELD

[0002] The present disclosure relates to carbon materials, particularly porous carbon materials comprising pores of various sizes, such as mixtures of micropores, mesopores, and macropores. The present disclosure also relates to methods for obtaining carbon materials, particularly porous carbon materials comprising two or more of micropores, mesopores, and macropores. In addition, the present disclosure relates to the use of carbon materials, particularly porous carbon materials comprising two or more of: micropores, mesopores, and macropores, in particular those obtained from the methods described herein.BACKGROUND

[0003] Carbon materials synthesised by carbonisation and / or pyrolysis typically have limited porosity. This lack of porosity means these carbon materials contain a relatively small number of active sites. The active sites of carbon material can be crucial for various industries including, but not limited to: catalysis, gas adsorption, energy storage, and environmental remediation. These active sites may serve as the locations on the material surface where chemical reactions or adsorption processes occur.

[0004] Emerging porous carbon materials have attracted considerable attention due to their exceptional properties including: large specific surface areas, tuneable porosity, high electrical conductivity, and chemical stability. Compared to conventional activated carbon with uniform pore dimensions, usually less than 2 nm, porous carbon materials may possess a more complex hierarchical pore structure which is strategies to improve the porosity and permeability of carbon materials are even more innovative and beneficial to expand their potential as active materials.

[0005] Many widely existing natural materials and artificial materials are good carbon precursors. However, the lack of effective pore-making technology restricts them from becoming important contributors to the development of the low-carbon economy. Therefore, it is of important to develop efficient techniques for the synthesis of hierarchically porous carbon. To date, only limited strategies, such as plasma technique, activation, and porous carbonaceous material decoration, have been developed to fabricate carbon materials with pores on a plurality of scales, such as materials with both mesopores and macroporous topography from off-the-shelf carbon materials or precursor carbon materials.

[0006] Conventional “bottom-up” methodologies, which entail the addition of removable template agents during precursor formation allow the synthesis of carbon materials consisting of controlled mesopores and macropores. However, templating methods exhibit restrictions when applied to precursors already existing in their natural or artificial form.

[0007] In contrast, “up-bottom” strategies, involving the direct carbonization of diverse carbon sources followed by physical or chemical activation, grapple with the complexities of preserving a well-tailored meso / macro-porous framework in carbon. The stringent requirements for the topographical structures for various enhanced performances make this strategy limited to very few success cases.

[0008] Optimizing the number of active sites in porous carbon materials is crucial for enhancing these materials' performance and efficiency in various applications, including those in environmental, energy, and chemical industries. The present disclosure seeks to provide alternative porous carbon materials with improved properties for industrial application. In addition, the present disclosure, in part, also seeks to provide an alternative method to produce porous carbon materials that may overcome some of the disadvantages associated with the known methods described above.

[0009] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is solely for the purpose of providing a context for the present disclosure. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each claim of this application.SUMMARY

[0010] In a first aspect, disclosed herein is a method of forming a carbon material comprising a plurality of pores, the method comprising: heating an activated precursor material comprising an activating material and a precursor material that comprises carbon to a first temperature; optionally, pyrolyzing at least a portion of the activated precursor material; and introducing an active gas to the activated precursor material to react with at least a portion of the carbon in the activated precursor material to form the carbon material comprising a plurality of pores.

[0011] In a second aspect, disclosed herein is a carbon material comprising a plurality of pores, when produced by the method according to the first aspect.

[0012] In a third aspect, disclosed herein is a carbon material comprising a plurality of mesopores and macropores, wherein the carbon material has one or more of a Brunauer-Emmett-Teller (BET) surface area (in m2 / g) of greater than about 500, 750, 1000, or 1500; a bimodal pore size distribution comprising a first peak and a second peak, wherein a first peak is in the range of between about 1 nm to about 50 nm, and wherein the second peak is in the range of between about 50 nm to about 600 nm; between about 10 to 90 (% v / v) of pores have a pore size (in nm) of between about 1 to about 50, or between about 20 to 40; between about 10 to 90 (% v / v) of pores have a pore size (in nm) of between about 50 to about 600, or between about 60 to 200; a pore volume (in cm3 / g) of between about 0.5 to about 1.0, or between about 0.7 to about 0.9; an average pore depth (nm) of between about 10 to about 900, between about 10 to about 500, between about 100 to about 500, between about 200 to about 400, or between about 300 to about 400; an ID / IG ratio (i.e. level of disordered carbon) of more than about than 0.6, optionally in a range of about 0.8 to about 1.2; an electrical conductivity (in S / m) of between about 101to about 106, or between about 102to about 104;a thickness (in nm) of between about 1 to about 100, or between about 2 to about 20; a diameter (in pm) of between about 0.1 to about 200, or between about 10 to about 50; and a density (in kg / m3) of between about 0.1 to about 2.2, or between about 1.2 to about 1.5.

[0013] In a fourth aspect, disclosed herein is an article comprising or composed of the carbon material of the second or third aspect.

[0014] In a fifth aspect, disclosed herein is use of the carbon material of the second or third aspect, as: an adsorbent, an absorbent, an electrode material, as a catalyst support, in water purification, in electrocatalysis, in supercapacitor, battery, carbon capture, electromagnetic wave absorption, gas / chemical separation and sensor.

[0015] Advantageously, the carbon materials of the present disclosure, and those obtained from the method described herein, may possess a highly desirable hierarchically organised porous structure. For example, materials with pores on different scales, including the in the microporous range (pore size < 2 nm), the mesoporous range (2 nm < pore size < 50 nm) and / or macroporous range (pore size > 50 nm). The presence of both mesopores and microporous range. Materials comprising pores on both the mesoporous and microporous scale may provide not only a high surface area for active site dispersion but can also reduce resistance to mass transport throughout the material allowing for chemical species to readily diffuse to available active sites.

[0016] Advantageously, the method of the present disclosure can be applied to a wide variety of carbon-based materials, including those mater or precursor material comprising carbon. Compared with conventional activation methods which mainly produce micropores and small mesopores of less than 10 nm, the method disclosed herein can potentially allow for the production of porous carbon materials uniform distribution of pores within the material having a diameter in the range of about 10-500 nm. The method described herein may also allow for the conversion of a carbon material and / or a precursor material comprising carbon into a graphene-like ultrathin carbon film with a thickness of about 2 to about 20 nm. Furthermore, the method described herein can be scalable and, in one or more embodiments, may not require redundant chemicals meaning it can potentially be implemented in existing carbonization furnaces.BRIEF DESCRIPTION OF DRAWINGS

[0017] Various embodiments of the present disclosure will be further described and illustrated, by way of example only, with reference to the accompanying drawings in which:Figure 1 - Scanning electron microscopy (SEM) images of the surface morphology of porous carbon fibre prepared according to Example 1.Figure 2 - BET surface area, pore size distribution, atomic force microscopy (AFM) surface topology and pore depth distribution of porous carbon fibre prepared according to Example 1.Figure 3 - Phase structure identification from -X-ray diffraction (XRD) and Raman spectra of traditional carbon fibre, activated carbon fibre and porous carbon fibre prepared according to Example 1.Figure 4 - SEM images of the surface morphology of porous carbon fibre prepared according to Example 2.Figure 5 - SEM images of the surface morphology of porous carbon fibre prepared according to Example 3.Figure 6 - SEM images of the surface morphology of porous carbon fibre prepared according to Example 4, using wastepaper (left), activated carbon fibre (middle) and high-strength carbon fibre (right) as the precursor material.Figure 7 - SEM images of the surface morphology of porous carbon fibre prepared according to Example 5, using potassium chloride (left), potassium sulphate (middle) and calcium chloride (right) as the activating material.Figure 8 - Influence of active gas content on pore formation.Figure 9 - Influence of air on pore formation.Figure 10 - Influence of dwell time on pore formation.Figure 11 - Influence of amount of activating material on pore formation.Figure 12 - Bacteria interception.Figure 13 - Supercapacitor data.Figure 14 - An embodiment of the method of the present disclosure.DESCRIPTION OF EMBODIMENTSGeneral terms

[0018] In the following description, reference is made to the accompanying drawings which form a part hereof, and which is shown, by way of illustration, several embodiments. It is understood that other embodiments may be used, and structural changes may be made without departing from the scope of the present disclosure.

[0019] With regards to the definitions provided herein, unless stated otherwise, or implicit from context, the defined terms and phrases include the provided meanings. Unless explicitly stated otherwise, or apparent from context, the terms and phrases below do not exclude the meaning that the term or phrase has acquired by a person skilled in the relevant art. The definitions are provided to aid in describing particular embodiments, and are not intended to limit the claimed invention, because the scope of the invention is limited only by the claims. Furthermore, unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular.

[0020] All publications discussed and / or referenced herein are incorporated herein in their entirety.

[0021] Throughout this disclosure, unless specifically stated otherwise or the context requires otherwise, reference to a single step, composition of matter, group of steps or group of compositions of matter shall be taken to encompass one and a plurality (i.e., one or more) of those steps, compositions of matter, groups of steps or groups of compositions of matter. Thus, as used herein, the singular forms “a”, “an” and “the” include plural aspects unless the context clearly dictates otherwise. For example, reference to “a” includes a single as well as two or more; reference to “an” includes a single as well as two or more; reference to “the” includes a single as well as two or more and so forth.

[0022] Those skilled in the art will appreciate that the disclosure herein is susceptible to variations and modifications other than those specifically described. It is to be understood that the disclosure includes all such variations and modifications. The disclosure also includes all of the examples, steps, features, methods, compositions, coatings, processes, and coated substrates, referred to or indicated in this specification, individually or collectively, and any and all combinations or any two or more of said steps or features.

[0023] The term “and / or”, e.g., “X and / or Y” shall be understood to mean either “X and Y” or “X or Y” and shall be taken to provide explicit support for both meanings or for either meaning.

[0024] As used herein, the phrase “at least one of’, when used with a list of items, means different combinations of one or more of the listed items may be used and only one of the items in the list may be needed. The item may be a particular object, thing, or category. In other words, “at least one of’ means any combination of items or number of items may be used from the list, but not all of the items in the list may be required. For example, and without limitation, “at least one of item A, item B, and item C” may mean item A; item B; item C; item A and item B; item A and item C; item B and item C; item A, item B, and item C. In some cases, “at least one of item A, item B, and item C” may mean, for example and without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or some other suitable combination.

[0025] As used herein, the term “about”, unless stated to the contrary, typically refers to + / - 10%, for example + / - 5%, of the designated value.

[0026] Unless otherwise indicated, the terms “first,” “second,” etc., are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to a “second” item does not require or preclude the existence of lower-numbered item (e.g., a “first” item) and / or a higher-numbered item (e.g., a “third” item).

[0027] It is to be appreciated that certain features that are, for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub-combination.

[0028] Throughout the present specification, various aspects and components of the invention can be presented in a range format. The range format is included for convenience and should not be interpreted as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible sub-ranges as well as individual numerical values within that range, unless specifically indicated. For example, description of a range such as from 1 to 5 should be considered to have specifically disclosed sub-ranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 5, from 3 to 5 etc., as well as individual and partial numbers within the recited range, for example, 1, 2, 3, 4, 4.5 or 5,unless where integers are required or implicit from context. This applies regardless of the breadth of the disclosed range. Where specific values are required, these will be indicated in the specification.

[0029] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps. The phrase “consisting of’ means the enumerated elements and no others.

[0030] The phrase “substantially consists of’, will be understood by the person skilled in the art. The term “substantially” may also include embodiments with “entirely”, “completely”, “all”, etc. Hence, in embodiments the adjective substantially may also be removed. Where applicable, the term “substantially” may also relate to 90% or higher, such as 95% or higher, especially 99% or higher, even more especially 99.5% or higher, including 100%.

[0031] The reference to “substantially free” generally refers to the absence of that compound or component in the composition other than any trace amounts or impurities that may be present, for example this may be an amount by volume % in the total composition of less than about 3%, 2% 1%, 0.1%, 0.01%, 0.001%, or 0.0001%.

[0032] In one embodiment, the reference to STP, or standard temperature and pressure, will be understood by the person skilled in the art to mean a temperature of 0 °C and an absolute pressure of 1 bar. In another embodiment, the reference to STP, or standard temperature and pressure, will be understood by the person skilled in the art to mean a temperature in a range of 400 to 1000 °C and a pressure of 0.1 to 10 atm (bar).Method

[0033] The present disclosure generally relates to a method of forming a carbon material. Disclosed herein is a method of forming a carbon material comprising a plurality of pores, the method comprising: heating an activated precursor material comprising an activating material and a precursor material that comprises carbon to a first temperature; optionally, pyrolyzing at least a portion of the activated precursor material;introducing an active gas to the activated precursor material to react with at least a portion of the carbon in the activated precursor material to form the carbon material comprising a plurality of pores.

[0034] In one embodiment, there is provided a method of forming a carbon material comprising a plurality of pores, the method comprising: heating an activated precursor material comprising an activating material and a precursor material that comprises carbon to a first temperature; and introducing an active gas to the activated precursor material to react with at least a portion of the carbon in the activated precursor material to form the carbon material comprising a plurality of pores.

[0035] In some embodiments, the method further comprises pyrolyzing at least a portion of the activated precursor material prior to introducing the active gas.

[0036] Herein, the carbon material formed may be produced in an array of forms, including, but not limited to the form of: a carbon fibre, a carbon film, and / or a carbon powder. The carbon material may be a porous carbon material, for example a porous carbon fibre and / or a porous carbon powder.

[0037] In one embodiment, the carbon material is formed by introducing an active gas to an activated precursor material comprising carbon to react the active gas with at least a portion of the carbon in the activated precursor material to form the carbon material, optionally and porous carbon material or carbon film.

[0038] In one embodiment the carbon material comprises a plurality of pores.

[0039] In one embodiment at least a portion of the plurality of pores have a diameter of: less than about 2 nm; about 2 to about 50 nm; greater than about 50 nm; or a combination thereof. In another embodiment, at least a first portion of the plurality of pores have a diameter of about 2 to about 50 nm; and at least a second portion of the plurality of pores have a diameter greater than about 50 nm. In yet another embodiment, at least a first portion of the plurality of pores have a diameter of less than about 2 nm; at least a second portion of the plurality of pores have a diameter of about 2 to about 50 nm; and at least a third portion of the plurality of pores have a diameter greater than about 50 nm.

[0040] The inventors of the present disclosure have discovered that by controlling various parameters, including but not limited to: the composition (e.g. the composition of the precursor material), flow rate of one or more active gases, and / or various conditions within a reaction vessel (for example temperature and / or residence time), the degree of interaction between one more active gas, activating material, and precursor material may be modulated thereby, ideally providing an element of control to the intensity of carbon oxidation. The ability to control the intensity of carbon oxidation, allows for a degree of control of the resulting morphology of the carbon material formed, including, for example, the pore diameter, pore depth, pore volume and / or pore distribution. Advantageously, the carbon materials formed from the method described herein may require little additional treatment, before being ready for use in a broad range of applications.MaterialsCarbon material

[0041] For brevity, herein “carbon material comprising a plurality of pores” can be referred to as “carbon material”.

[0042] The inventors of the present disclosure have discovered that through appropriate selection of a precursor material and careful control of various process conditions, including, but not limited to: flow rates, temperature and / or compositions, that a diverse range of carbon materials can be obtained from a wide variety of precursor materials. The final form can be carbon material may be, at least partially, determined by the type of precursor material selected.

[0043] In some embodiments, at least a portion of the carbon material is a carbon fibre, a carbon film, a carbon powder, and combinations thereof. In some embodiments, at least a portion of the carbon material is in the form of a porous carbon fibre. In some embodiments, at least a portion of the carbon material is in the form of a carbon film. In some embodiments, at least a portion of the carbon material is in the form of a carbon powder, optionally a porous carbon powder.

[0044] The carbon material may be in the form of a powder. When in the form of powder, the carbon material may have a particle size, e.g. size (in pm) of about 0.1-2000 pm, which is optionally dependent on the particle size of a precursor. For example, the particle size or diameter may be about 0.1 to about 5000 pm, or about 5 to about 500 pm. For example, the particle size or diameter (in pm), may be about, at least about or lessthan about: 0.1, 0.5, 1, 5, 10, 15, 20, 25, 50, 100, 150, 200, 250, 500, 750, 100, 1250, 1500, or 2000. The particle size or diameter may be in a range provided by any two of these upper and / or lower values. The particle size or diameter may be measured by an appropriate method known in the art; for example ASTM D2862-16 Standard Test Method for Particle Size Distribution of Granular Activated Carbon (as updated 29 September 2022).

[0045] The carbon material may be in the form of a film, for example an ultrathin film. When in the form of a film, the carbon material may have a thickness (in nm) of about, or at least about 1 to about 200 nm. For example, in a range of about 1 to about 150 nm, about 1 to about 100 nm, about 50 to about 200 nm, or about 100 to about 200 nm. The thickness may be measured by an appropriate method known in the art; for example ASTM D6988-21 (as updated 16 November 2021).

[0046] The carbon material may be in the form of a fibre. When in the form of a fibre, the carbon material may have a thickness, e.g. diameter (in pm) of about 0.1-100 pm, which is optionally dependent on the diameter of a precursor. For example, the thickness or diameter may be about 0.1. to about 50 pm, or about 50 to about 100 pm. The thickness or diameter may be measured by an appropriate method known in the art. For example a person skilled in the art may use one or more of: a digital micrometer, microscope, airflow measurement, linear density measurement, or a mixture thereof. One or more known standards may be used. For example, ASTM D2130-22: Standard test method for diameter of wool and other animal fibers by microprojection (as updated 11 August 2022); and / or ASTM D276: Standard Test methods for identification of fibers in textiles (as updated 25 January 2021.

[0047] In some embodiments, the carbon content in the carbon material (w / w) is about, or at least about: 80, 81, 82, 83, 84, 85, 86, 87, 88, 89 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8, 99.9, 99.91, 99.92, 99.93, 99.94, 99.95, 99.96, 99.97, 99.98, 99.99, 99.991, 99.992, 99.993, 99.994, 99.995, 99.996, 99.997, 99.998, or 99.999. In some embodiments the carbon content in the carbon material (w / w) is less than about: 99.999, 99.998. 99.997. 99.996. 99.995, 99.994, 99.993, 99.992, 99.991, 99.99, 99.98. 99.97. 99.96. 99.95, 99.94, 99.93, 99.92, 99.91, 99.9, 99.8. 99.7. 99.6. 99.5, 99.4, 99.3, 99.2, 99.1, 99, 98, 97, 96, 95, 94, 93, 92, 91, 90, 89, 88, 87, 86, 85, 84, 83, 82, 81, or 80. The amount of carbon in the carbon material (w / w) may be in a range provided by any two of these upper and / or lower values, for example the carbon content in the carbon material (w / w) described herein may be between about 80 to about99.999, between about 90 to about 99.999, or between about 99 to about 99.999. The carbon content may be measured by an appropriate method known in the art; for example the carbon content may be determined by dry combustion using an elemental analyser. Alternatively, or in addition, the person skilled in the art may use and / or apply ASTM D7633-13(2018) Standard Test Method for Carbon Black - Carbon Content (as updated 14 July 2022).

[0048] In some embodiments, the carbon material substantially consists of carbon.

[0049] In some embodiments, the carbon material comprises a Brunauer-Emmett- Teller (BET) surface area (in m2 / g) of greater than about 500, 750, or 1000, wherein the specific surface area is calculated by the BET method. In some embodiments, the carbon material comprises a BET surface area (in m2 / g) of about, at least about, or less than about: 500, 520, 540, 560, 580, 600, 620, 640, 660, 680, 700, 720, 740, 760, 780, 800, 820, 840, 860, 880, 900, 920, 940, 960, 980, 1000, 1100, 1200, 1300, 1400, or 1500. The BET surface area may be in a range provided by any two of these upper and / or lower values. The BET surface area may be measured by an appropriate method known in the art; for example, one or more of: ISO 9277:2022 - Determination of the specific surface area of solids by gas adsorption — BET method; ASTM D 4820 Standard Test Methods for Carbon Black — Surface Area by Multipoint B.E.T. Nitrogen Adsorption (as updated 18 February 2021); and / or ASTM D8325-20 - Standard Guide for Evaluation of Nuclear Graphite Surface Area and Porosity by Gas Adsorption Measurements (as approved 1 June 2020).

[0050] In some embodiments, the carbon material comprises a bimodal pore size distribution comprising a first peak and a second peak, wherein a first peak is in the range of between about 1 nm to about 50 nm, and wherein a second peak is in the range of between about 50 nm to about 600 nm. In some embodiments, the carbon material comprises a trimodal pore size distribution comprising a first peak, a second peak and a third peak, wherein a first peak is at less than about 2 nm, a second peak is in the range of between about 2 nm to about 50 nm, and wherein a third peak is in the range of between about 50 nm to about 600 nm. This parameter may be measured by an appropriate method known in the art; for example, one or more of: ISO 15901-2:2022(en) - Pore size distribution and porosity of solid materials by mercury porosimetry and gas adsorption — Part 2: Analysis of nanopores by gas adsorption; ASTM D4607 - Determination of Iodine Number of Activated Carbon (as updated 3 June 2021); ASTM D2862-10 - Standard Test Method for Particle Size Distribution of Granular Activated Carbon;and / or ISO 21340:2017 Test methods for fibrous activated carbon (as updated 15 July 2016).

[0051] In some embodiments, the carbon material comprises between about 1 to 99 (% v / v) of pores with a pore size of less than about 2 nm. For example, in some embodiments the carbon material comprises about, at least about, or less than about (in % v / v): 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, of pores with a pore size (in nm) of less than about 2 nm. This parameter may be measured by an appropriate method known in the art; for example: ISO 15901-2:2022(en) - Pore size distribution and porosity of solid materials by mercury porosimetry and gas adsorption — Part 2: Analysis of nanopores by gas adsorption; and / or ASTM D4607 - Determination of Iodine Number of Activated Carbon (as updated 3 June 2021).

[0052] In some embodiments, the carbon material comprises between about 10 to 99 (% v / v) of pores with a pore size (in nm) of between about 1 to about 50, or between about 1 to 20. For example, in some embodiments the carbon material comprises about, at least about, or less than about (in % v / v): 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, of pores with a pore size (in nm) of about, at least about, or less than about: 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, or 50. This parameter may be measured by an appropriate method known in the art; for example: ISO 15901-2:2022(en) - Pore size distribution and porosity of solid materials by mercury porosimetry and gas adsorption — Part 2: Analysis of nanopores by gas adsorption; and / or ASTM D4607 - Determination of Iodine Number of Activated Carbon (as updated 3 June 2021).

[0053] In some embodiments, the carbon material comprises between about 10 to 90 (% v / v) of pores with a pore size (in nm) of between about 50 to about 600, or between about 65 to 200. For example, in some embodiments the carbon material comprises about, at least about, or less than about (in % v / v): 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, with a pore size (in nm) of about, at least about, or less than about: 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175, 180, 185, 190, 195, 200, 250, 300, 350, 400, 450, 500, 550 or 600. This parameter may be measured by an appropriate method known in the art; for example ISO 15901-2:2022(en) - Pore size distribution and porosity of solid materials by mercury porosimetry and gas adsorption — Part 2: Analysis of nanopores by gas adsorption.

[0054] In some embodiments, the carbon material comprises a pore volume (in cm3 / g) of between about 0.5 to about 1.0, or between about 0.7 to about 0.9. For example, in some embodiments, the carbon material comprises a pore volume (in cm3 / g) of about, at least about, or less than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, or 1.0. The pore volume may be measured by an appropriate method known in the art; for example one or more of: gravimetric method, mercury porosimeters, and / or gas porosimeters (by measuring the volume of liquid or gas that penetrated the sample); ISO 15901-2:2022(en)- Pore size distribution and porosity of solid materials by mercury porosimetry and gas adsorption — Part 2: Analysis of nanopores by gas adsorption; and / or ASTM D8325-20- Standard Guide for Evaluation of Nuclear Graphite Surface Area and Porosity by Gas Adsorption Measurements (as approved 1 June 2020).

[0055] In some embodiments, the carbon material comprises an average pore depth (nm) of between about 10 to about 900, between about 200 to about 400, or between about 300 to about 400. In some embodiments, the carbon material comprises an average pore depth (nm) of about, at least about, or less than about: 10, 20, 40, 60, 80, 100, 120, 140, 160, 180, 200, 220, 240, 260, 280, 300, 320, 340, 360, 380, 400, 420, 440, 460, 480, 500, 520, 540, 560, 580, 600, 620, 640, 660, 680, 700, 720, 740, 760, 780, 800, 820, 840, 860, 880, or 900. The average pore depth (nm), may be in range of any two of the stated values. The average pore depth may be measured by an appropriate method known in the art; for example by using atomic force microscopy.

[0056] In some embodiments, the carbon material comprises an ID / IG ratio (i.e. level of disordered carbon) of more than about 0.6. For example, the ID / IG ratio may be more than about 0.6, 0.7, 0.8, 0.9, 1.0, 1.1 or 1.2, or in a range of about 0.9 to about 1.2. The ID / IG ratio may be measured by an appropriate method known in the art; for example by using Raman spectroscopy.

[0057] In some embodiments, the carbon material comprises an electrical conductivity (in S / m) of between about 101to about 106, or between about 102to about 104. For example, in some embodiments, the carbon material comprises an electrical conductivity (in S / m) of about, at least about or less than about: 101, 102, 103, 104, 105, or 106. The conductivity may be measured by an appropriate method known in the art; for example: ASTM C611-21 - Standard Test Method for Electrical Resistivity of Manufactured Carbon and Graphite Articles at Room Temperature (as approved 1 May 2021); and / or ASTM D4496-21 - Standard test method for D-C resistance or conductance of moderately conductive materials (as updated 8 December 2022).

[0058] In some embodiments, the carbon material comprises a thickness (in nm) of between about 1 to about 100, or between about 2 to about 20. For example, in some embodiments, the carbon material comprises a thickness (in nm) of about, at least about, or less than about: 1, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100. The thickness may be measured by an appropriate method known in the art.

[0059] In some embodiments, the carbon material comprises a diameter (in pm) of between about 0.1 to about 200, or between about 1 to about 20, or between about 10 to about 50. For example, in some embodiments, the carbon material comprises a diameter (in pm) of about, at least about, or less than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95,100, 125, 150 or 200. The diameter may be measured by an appropriate method known in the art.

[0060] In some embodiments, the carbon material comprises a density (in kg / m3) of between about 0.1 to about 2.2, or between about 1.2 to about 1.5. For example, in some embodiments, the carbon material comprises a density (in kg / m3) of about, at least about, or less than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2. The density may be measured by an appropriate method known in the art.Precursor material

[0061] The precursor material may be a carbon material or a material comprising carbon, wherein at least a portion of which can be pyrolyzed to carbon. In some embodiments, the precursor material is selected from: a material substantially consisting of carbon, a material comprising carbon, and combinations thereof. In some embodiments, the precursor material is selected from: a material substantially consisting of carbon. In some embodiments, the precursor material is selected from: a material comprising carbon. In some embodiments, the precursor material is selected from, but not limited to: activated carbon, activated carbon fibre, high-performance carbon fibre, recycled carbon fibre, biochar, carbon black, graphene, graphite, coal, pitch, cotton, jute, bamboo, paper, wood, nutshell, coconut shell, coconut fibre (Coir), viscose fibre, polyacrylonitrile fibre, semi-synthetic fibres, and combinations thereof.

[0062] In some embodiments, the carbon content in the precursor material (w / w) is about, or at least about: or greater than about: 50, 52, 54, 56, 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78, 80, 82, 84, 86, 88, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 99.1, 99.2, 99.3,99.4, 99.5, 99.6, 99.7, 99.8, 99.9, 99.91, 99.92, 99.93, 99.94, 99.95, 99.96, 99.97, 99.98, 99.99, 99.991, 99.992, 99.993, 99.994, 99.995, 99.996, 99.997, 99.998, or 99.999. In some embodiments, the carbon content in the precursor material (w / w) is less than about: 99.999, 99.998. 99.997. 99.996. 99.995, 99.994, 99.993, 99.992, 99.991, 99.99, 99.98. 99.97. 99.96. 99.95, 99.94, 99.93, 99.92, 99.91, 99.9, 99.8. 99.7. 99.6. 99.5, 99.4, 99.3, 99.2, 99.1, 99, 98, 97, 96, 95, 94, 93, 92, 91, 90, 88, 86, 84, 82, 80, 78, 76, 74, 72, 70, 68, 66, 64, 62, 60, 58, 56, 54, 52, or 50. The amount of carbon in the carbon material (w / w) may be in a range provided by any two of these upper and / or lower values, for example the carbon content in the carbon material (w / w) described herein may be between about 50 to about 99.999, between about 60 to about 99.999, between about 70 to about 99.999, or between about 80 to about 99.999.

[0063] In some embodiments, the precursor material is a naturally occurring material comprising carbon.

[0064] In some embodiments, the precursor material is selected from: natural fibres, such as cotton, jute, bamboo and coconut fibre, semi -synthetic fibres, viscose fibre, activated carbon fibre and carbon fibres, and combinations thereof. The inventors of the present disclosure have discovered that these precursor materials are well suited for use in the method described herein when is it desired to form a carbon fibre, optionally a porous carbon fibre.

[0065] In some embodiments, the precursor material is selected from, but not limited to: biomass, activated carbon, coal and pitch, and combinations thereof. Non-limiting examples of biomass include, but are not limited to: biochar, paper, wood, nutshell and coconut shell. The inventors of the present disclosure have discovered that these precursors materials are well suited for use in the method described herein, for example when is it desired to form carbon powder, optionally a porous carbon powder.

[0066] In some embodiments, the precursor material is selected from, but not limited to: natural fibres, such as cotton, bamboo, coconut fibre and other hollow fibres. The inventors of the present disclosure have discovered that these precursors materials are well suited for use in the method described herein, for example when is it desired to form a carbon film.Templating agent

[0067] In some embodiments, the method does not comprise the use of a templating agent. For example, a templating agent selected from, but not limited to: : silica, a zeolite, Ca2CCh, AI2O3, NaCl, ZnCh, Na2CCh, one or more surfactants, a polymer, such as a thermally decomposed polymers (for example polystyrene (PS), polyvinyl acetate (PVA), polymethacrylate (PMMA), and / or polyurethane (PU)_, a block copolymer, and mixtures thereof.Activating material

[0068] The inventors of the present application have surprisingly discovered that by introducing an active gas to an activated precursor material as described herein, desirable carbon materials may be obtained. Without being limited to theory, the inventors find that the activating material in the activated precursor material can facilitate carbon oxidisation at elevated temperatures, which can enable the regulation of pore formation in the carbon material, particularly in the formation of mesopores and / or macropores.

[0069] In some embodiments, the activating material comprises at least one metal selected from, but not limited to: an alkali metal, an alkali earth metal, a transition metal, and combinations thereof.

[0070] In some embodiments, the activating material comprises at least one metal oxide, wherein the metal is selected from, but not limited to: an alkali metal, an alkali earth metal, a transition metal, and combinations thereof.

[0071] In some embodiments, the activating material comprises at least one of: a salt of an alkali metal, an alkali earth metal, a transition metal, or a combination thereof.

[0072] In some embodiments, the activating material is selected from, but not limited to: potassium carbonate, potassium bicarbonate, potassium hydroxide, sodium carbonate, sodium hydroxide, sodium bicarbonate, lithium hydroxide, potassium chloride, sodium chloride, lithium chloride, calcium chloride, potassium sulphate, iron sulphate, iron chloride, zinc chloride, nickel nitrate, cobalt nitrate, and combinations thereof.

[0073] In some embodiments, the activating material is selected from, but not limited to: potassium carbonate, potassium hydroxide, sodium carbonate, sodium hydroxide, sodium bicarbonate, lithium hydroxide, potassium chloride, sodium chloride, lithiumchloride, calcium chloride, potassium sulphate, iron sulphate, iron chloride, zinc chloride, nickel nitrate, cobalt nitrate, and combinations thereof.

[0074] In some embodiments, the activating material is selected from: a salt of potassium, sodium, calcium, and combinations thereof.

[0075] In some embodiments, the activating material is selected from: potassium hydroxide, potassium carbonate, calcium chloride, or a combination thereof.Activating solution

[0076] In some embodiments, an activating solution is used for contacting the precursor material with activating material. The activating solution may comprise the activating material and a solvent. The solvent may be any suitable to suspend and / or dissolve the activating material. In order to facilitate dispersion of the activating agent in the solvent the solution may undergo heating and / or mechanical agitation, such as stirring, facilitating the distribution of the activating material in the solvent.

[0077] In some embodiments, the activating material is present in an activating solution prior to contact with the precursor material.

[0078] In some embodiments, the solvent is selected from, but not limited to: water, ethanol, and combinations thereof. In some embodiments, the activating solution is a homogeneous activating solution. In some embodiments, the activating solution is an aqueous activating solution.

[0079] In some embodiments, the activating material content in the activating solution (w / w) is about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 45, or 50. In some embodiments, the activating material in the activating solution (w / w) is less than about: 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1. The activating material in the activating solution (w / w) may be in a range provided by any two of these upper and / or lower values, for example the activating material content in the activating solution (w / w) described herein may be between about 0.1 to about 50, for example between about 0.1 to about 20.

[0080] In some embodiments, the activating solution further comprises a surfactant. The surfactant may be selected from, but not limited to: cetyltrimethylammonium bromide (CTAB), sodium dodecyl sulfate (SDS), a non-ionic surfactant, such as asurfactant that has a hydrophilic polyethylene oxide chain and an aromatic hydrocarbon lipophilic or hydrophobic group, e.g. Triton or 2-[4-(2,4,4-trimethylpentan-2- yl)phenoxy]ethanol, and mixture thereof. The addition of surfactants may serve to enhance the interaction between precursor material and the activating material and contributes to the overall effectiveness of the coating process and ensures a more homogeneous distribution of the activating material on the precursor materials.

[0081] In some embodiments, the surfactant content in the activating solution (w / w) is about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20. In some embodiments, the surfactant content in the activating solution (w / w) is less than about: 20, 19, 18, 17, 16, 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1. The surfactant content in the activating solution (w / w) may be in a range provided by any two of these upper and / or lower values, for example the surfactant content in the activating solution (w / w) described herein may be between about 0.1 to about 20, for example between about 1 to about 10.Activated precursor material

[0082] The activated precursor material comprises the activating material and the precursor material. In some embodiments, the activated precursor material substantially consists of the activating material and the precursor material.

[0083] In some embodiments, the activating material content in the activated precursor material (w / w) is about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20. In some embodiments, the activating material in the activated precursor material (w / w) is less than about: 20,19, 18, 17, 16, 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1. The amount of activating material in the activated precursor material (w / w) may be in a range provided by any two of these upper and / or lower values, for example the activating material content in the activated precursor material (w / w) described herein may be between about 0.1 to about20, between about 0.1 to about 10, or between about 1 to about 10.

[0084] In some embodiments, the precursor material content in the activated precursor material (w / w) is about, or greater than about: 80, 81, 82, 83, 84, 85, 86, 87, 88, 89 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8, or 99.9. In some embodiments, the precursor material in the activated precursor material (w / w) is less than about: 99.9, 99.8. 99.7. 99.6. 99.5, 99.4, 99.3, 99.2, 99.1, 99, 98, 97, 96, 95, 94, 93, 92, 91, 90, 89, 88, 87, 86, 85, 84, 83, 82, 81, or 80. The amount of precursormaterial in the activated precursor material (w / w) may be in a range provided by any two of these upper and / or lower values, for example the amount of precursor material content in the activated precursor material (w / w) described herein may be between about 80 to about 99.9, between about 90 to about 99.9, or between about 90 to about 99.Active gas

[0085] The active gas may be any gas capable of reacting with carbon. In some embodiments, the active gas is any gas capable of reacting with carbon to form carbon monoxide and / or carbon dioxide. In some embodiments, the active gas is or comprises a gas selected from oxygen, air, water / steam, ammonia, and combinations thereof. In some embodiments, the active gas is or comprises: oxygen, air, water / steam, and combinations thereof. In some embodiments, the active gas is or comprises oxygen, air, and combinations thereof. In some embodiments, the active gas is or comprises air. In some embodiments, the active gas is or comprises oxygen. In some embodiments, the active gas is or comprises water. In some embodiments, the active gas is or comprises ammonia.

[0086] The flow rate of the active gas (e.g., oxygen, ammonia, air, water / steam), may be controlled depending on factors such as precursor material. In some embodiments, the active gas is introduced at a flow rate (L / min STP per kg of activated precursor material) of about, or greater than about 0.01, 0.02, 0.03, 0.04, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3,4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950 or 1000 . In some embodiments, the active gas (e.g., oxygen, ammonia, air, water / steam), is introduced at a flow rate (L / min STP per kg of activated precursor material) of less than about 1000, 950, 900, 850, 800, 750, 700, 650, 600, 550, 500, 450, 400, 350, 300, 250, 200, 150, 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10,5, 4, 3, 2, 1 0.5, 0.4, 0.3, 0.2, 0.1, 0.05, 0.04, 0.03, 0.02, or 0.01. The flow rate of the active gas (e.g., oxygen, ammonia, air, water / steam), may be provided by any two of these upper and / or lower values, for example, the active gas is introduced at a flow rate (L / min STP per kg of activated precursor material) of between about 0.1 to about 1000, or between about 1 to about 500, or between about 10 to about 100. In some embodiments, the reaction vessel can be opened directly and let the active gas fill the entire atmosphere prior to the activation reaction starting.Carbon material comprising a plurality of pores

[0087] The method disclosed herein may be used to produce a carbon material comprising a plurality of pores.

[0088] Herein a carbon material comprising a plurality of pores may comprise pores on various different scales, for example on the micro, meso and / or macro scale. In one embodiment the carbon material comprises micropores, and pores on at least one of the meso or macro scale. In another embodiment the carbon material comprises mesopores, and pores on at least one of the micro or macro scale. In yet another embodiment the carbon material comprises macropores, and pores on at least one of the micro or meso scale.

[0089] In one embodiment at least a portion of the plurality of pores have a diameter of: less than about 2 nm; about 2 to about 50 nm; greater than about 50 nm; or a combination thereof. In another embodiment, at least a first portion of the plurality of pores have a diameter of about 2 to about 50 nm; and at least a second portion of the plurality of pores have a diameter greater than about 50 nm. For example, the carbon materials may comprise a plurality of pores, wherein at least a portion of the pores have a diameter of (in nm) of about: 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, and mixtures thereof. The pores having a diameter of greater than about 50 nm may have a maximum diameter of (in nm) about, at least about, or greater than about: 500, 475, 450, 425, 400, 375, 350, 325, 300, 275, 250, 225, 200, 175, 150, 125, 100, 75 or 50. In yet another embodiment, at least a first portion of the plurality of pores have a diameter of less than about 2 nm; at least a second portion of the plurality of pores have a diameter of about 2 to about 50 nm; and at least a third portion of the plurality of pores have a diameter greater than about 50 nm.

[0090] In another embodiment, at least about: 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% of the plurality of pores have a diameter that is less than about 2 nm.

[0091] In another embodiment, at least about: 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% of the plurality of pores have a diameter in a range of about 2 nm to about 50 nm.

[0092] In yet another embodiment, at least about: 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%,95% of the plurality of pores have a diameter greater than about 50 nm, for example in a range of about 50 to about 500 nm.

[0093] The pores may be measured by any appropriate means. The diameter distribution of pores less than 10 nm may be measured by a gas adsorption method, for example by a N2 adsorption method. For pores larger than 10 nm, methods such as Mercury Intrusion and Capillary Flow Porometry may be suitable. In addition, methods such as scanning electron microscopy (SEM) may also be used. For example, the diameter of pores larger than 10 nm may be measured by SEM images, and size distribution may be calculated based on at least 200 measurements. Mercury Intrusion and Capillary Flow Porometry methods may be suitable for measuring meso and / or macro pores.Process conditionsContacting conditions

[0094] In some embodiments, the method further comprises contacting the precursor material with an activating material to form the activated precursor material.

[0095] Contacting the precursor material with the activating material may be done at any suitable temperature. The temperature required may depend upon composition and / or structure of the precursor material and / or the activating material. In some embodiments, the contacting the precursor material comprising carbon with the activating material is performed at a temperature (°C) of about, or greater than about: 0, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100. In some embodiments, the contacting the precursor material comprising carbon with the activating material is performed at a temperature (°C) of less than about: 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, or 0. The temperature at which the contacting the precursor material comprising carbon with the activating material is performed of may be provided in a range provided by any two of these upper and / or lower values, for example, the contacting the precursor material comprising carbon with the activating material is performed at a temperature (°C) of: between about 0 to about 100, between about 10 to about 50, or between about 20 to about 30.

[0096] Contacting the precursor material with the activating material may be done for any suitable period of time to allow for the desired distribution of the activating material on the precursor material to be achieved. The period of time required may depend upon composition and / or structure of the precursor material and / or the activating material. Insome embodiments, the contacting the precursor material comprising carbon with the activating material is performed for a period of time (hours) of about, or greater than about: 0.1 0.5 1, 2, 3, 4, 5, 6, 9, 12, 18, 24, 36, 48, 60, 72, 96, 120, 144, 168, 192, 216, 240. In some embodiments, the contacting the precursor material comprising carbon with the activating material is performed for a period of time (hours) of less than about: 240, 216, 192, 168, 144, 120, 96, 72, 60, 48, 36, 24, 18, 12, 9, 6, 5, 4, 3, 2, 1, 0.5, or 0.1. The period of time for which the contacting the precursor material comprising carbon with the activating material is performed of may be provided in a range provided by any two of these upper and / or lower values, for example, the contacting the precursor material comprising carbon with the activating material is performed for a period of time (hours) of: between about 0.1 to about 240, between about 5 to about 120, or between about 24 to about 72.

[0097] In some embodiments, the ratio of activating solution to precursor material (w / w) is about, or greater than about: 1 : 1, 2: 1, 3: 1, 4: 1 5: 1, 6: 1, 7: 1, 8: 1, 9: 1, 10:1, 15: 1, 20: 1, 25: 1, 30: 1, 35: 1, 40:1, 45: 1, or 50: 1. In some embodiments, the ratio of activating solution to precursor material (w / w) is less than about 50: 1, 45: 1, 40:1, 35: 1 30: 1, 25: 1, 20: 1, 15: 1, 10:1, 9: 1, 8: 1, 7: 1, 6:1, 5: 1, 4: 1, 3: 1, 2: 1, or 1 :1. The ratio of activating solution to precursor material (w / w) may be provided in a range provided by any two of these upper and / or lower values, for example, the ratio of activating solution to precursor material (w / w) is between about 1 : 1 to between about 50: 1, or between about 5: 1 to between about 25: 1.Drying activated precursor material conditions

[0098] In some embodiments, after contacting the precursor material with the activating material to form the activated precursor material, the activated precursor material may be dried.

[0099] In some embodiments, the method further comprises drying the activated precursor material prior to heating to the first temperature.

[0100] When the precursor material is contacted with an activating solution, the drying may be performed to remove at least a portion of the solvent from the activated precursor material. The drying temperature required may depend upon composition and / or structure of the activating material, activating solution and / or the precursor material. In some embodiments, the drying of the activated precursor material is performed at a temperature (°C) of about, or greater than about: 20, 25, 30, 35, 40, 45, 50, 55, 60, 65,70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175, 180, 185, 190, 195, or 200. In some embodiments, the drying of the activated precursor material is performed at a temperature (°C) of less than about: 200, 195, 190, 185, 180, 175, 170, 165, 160, 155, 150, 145, 140, 135, 130, 125, 120, 115, 110, 105, 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, or 20. The temperature at which the drying of the activated precursor material is performed of may be provided in a range provided by any two of these upper and / or lower values, for example, the drying of the activated precursor material is performed at a temperature (°C) of: between about 20 to about 200, between about 40 to about 100, or between about 60 to about 80.

[0101] Drying the activated precursor material may be performed for any suitable period of time. The period of time required may depend upon composition and / or structure of the activating material, activating solution and / or the precursor material. In some embodiments, the drying of the activated precursor material is performed for a period of time (minutes) of about, or greater than about: 1, 2, 3, 4, 5, 10, 20, 30, 60, 120, 180, 240, 300, 360, 420, 480, 540, or 600. In some embodiments, the drying of the activated precursor material is performed for a period of time (minutes) of less than about: 600, 540, 480, 420, 360, 300, 240, 180, 120, 60, 30, 20, 10, 5, 4, 3, 2, or 1. The period of time for which the drying of the activated precursor material is performed of may be provided in a range provided by any two of these upper and / or lower values, for example, the drying of the activated precursor material is performed for a period of time (minutes) of: between about 1 to about 600, or between about 30 to about 120.

[0102] The drying may be performed in any suitable device. In some embodiments, the drying is performed in an oven. In some embodiments, the drying is performed in air. In some embodiments, the drying is performed in an inert atmosphere, for example a nitrogen and / or an argon atmosphere.Heating to a first temperature (pyrolyzing and / or reaction) condition

[0103] The activated precursor material may be heated to a first temperature. Depending on the composition of the precursor material the first temperature may be the temperature at which the activated precursor material is pyrolyzed and / or the temperature at which the reaction between the activated carbon material is reacted with the active gas.

[0104] In some embodiments, the heating to a first temperature is performed in a substantially inert atmosphere. In some embodiments, the substantially inert atmosphere comprises a first inert gas (e.g., nitrogen, argon or a combination thereof). In someembodiments, the heating to a first temperature is performed in the presence of a first inert gas. In some embodiments, the first inert gas is selected from nitrogen, argon, and combinations thereof.

[0105] In some embodiments, where pyrolyzing the precursor material is required, the first temperature is a pyrolyzing temperature.

[0106] Where pyrolyzing, the precursor material is not required, the first temperature may be the reaction temperature.

[0107] In some embodiments, heating the activated precursor material to a first temperature is performed at a rate (°C / min) of about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, 4, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50. In some embodiments, heating the activated precursor material to a first temperature is performed at a rate (°C / min) of less than about: 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, 4, 3, 2, 1 0.5, 0.4, 0.3, 0.2, or 0.1. The rate of heating of the activated precursor material to a first temperature may be provided by any two of these upper and / or lower values, for example, heating the activated precursor material to a first temperature is performed at a rate (°C / min) of between about 0.1 to about 50. In one embodiment, the heating the activated precursor material to a first temperature is performed at a rate (°C / min) of between about 1 to about 20.

[0108] The flow rate of the first inert gas may be controlled during heating. In some embodiments, the first inert gas is introduced at a flow rate (L / min) of about, or greater than about 0.01, 0.02, 0.03, 0.04, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100. In some embodiments, the first inert gas is introduced at a flow rate (L / min) of less than about 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, 4, 3, 2, 1 0.5, 0.4, 0.3, 0.2, 0.1, 0.05, 0.04, 0.03, 0.02, or 0.01. The flow rate of the first inert gas may be provided by any two of these upper and / or lower values, for example, the first inert gas is introduced at a flow rate (L / min) of between about 0.01 to about 100, or between about 0.5 to about 5.

[0109] The flow rate of the first inert gas may be controlled during heating. In some embodiments, the first inert gas is introduced at a flow rate (L / min STP per kg of precursor material) of about, or greater than about 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175, 180, 185, 190, 195, or200. In some embodiments, the first inert gas is introduced at a flow rate (L / min per gram of precursor material) of less than about 200, 195, 190, 185, 180, 175, 170, 165, 160, 155, 150, 145, 140, 135, 130, 125, 120, 115, 110, 105, 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, 4, 3, 2, 1 0.5, 0.4, 0.3, 0.2, 0.1. The flow rate of the first inert gas may be provided by any two of these upper and / or lower values, for example, the first inert gas is introduced at a flow rate (L / min per gram of precursor material) of between about 0.1 to about 200, between about 1 to about 100, or between about 25 to about 75.Pyrolyzing conditions

[0110] In some embodiments, it is required to pyrolyze the activated precursor material. Pyrolyzing the activated precursor material decomposes at least a portion of the precursor material and ideally reduces the non-carbon content of the precursor material.

[0111] In some embodiments, pyrolyzing the activated precursor material is performed in a substantially inert atmosphere. In some embodiments, the substantially inert atmosphere comprises a second inert gas (e.g., nitrogen, argon or a combination thereof). In some embodiments, the pyrolyzing is performed in the presence of a second inert gas. In some embodiments, the composition of the second inert gas is the same as the composition of the first inert gas. In some embodiments, the second inert gas is selected from nitrogen, argon, and combinations thereof.

[0112] The pyrolyzing of the activated precursor material may be performed in any suitable reaction vessel, for example an oven or a furnace.

[0113] The flow rate of the second inert gas may be controlled during pyrolyzing to remove reaction products. In some embodiments, the second inert gas is introduced at a flow rate (L / min) of about, or greater than about 0.01, 0.02, 0.03, 0.04, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100. In some embodiments, the second inert gas is introduced at a flow rate (L / min) of less than about 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, 4, 3, 2, 1 0.5, 0.4, 0.3, 0.2, 0.1, 0.05, 0.04, 0.03, 0.02, or 0.01. The flow rate of the second inert gas may be provided by any two of these upper and / or lower values, for example, the second inert gas is introduced at a flow rate (L / min) of between about 0.01 to about 100, or between about 0.5 to about 5.

[0114] The flow rate of the second inert gas may be controlled during heating. In some embodiments, the second inert gas is introduced at a flow rate (L / min STP per kg of precursor material) of about, or greater than about 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175, 180, 185, 190, 195, or 200. In some embodiments, the second inert gas is introduced at a flow rate (L / min per gram of precursor material) of less than about 200, 195, 190, 185, 180, 175, 170, 165, 160, 155, 150, 145, 140, 135, 130, 125, 120, 115, 110, 105, 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, 4, 3, 2, 1 0.5, 0.4, 0.3, 0.2, 0.1. The flow rate of the second inert gas may be provided by any two of these upper and / or lower values, for example, the first inert gas is introduced at a flow rate (L / min per gram of precursor material) of between about 0.1 to about 200, between about 1 to about 100, or between about 25 to about 75.

[0115] The pyrolyzing temperature required may depend upon composition of the precursor material and / or the desired structure of the carbon material. In some embodiments, the pyrolyzing of the activated precursor material is performed at a temperature (°C) of about, or greater than about: 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, or 1000. In some embodiments, the pyrolyzing of the activated precursor material is performed at a temperature (°C) of less than about: 1000, 950, 900, 850, 800, 750, 700, 650, 600, 550, 500, 450, or 400. The temperature at which the pyrolyzing of the activated precursor material is performed of may be provided in a range provided by any two of these upper and / or lower values, for example, the pyrolyzing the activated precursor material is performed at a temperature (°C) of: between about 400 to about 1000, between about 450 to about 950, or between about 500 to about 900.

[0116] Pyrolyzing the activated precursor material may be performed for any suitable period of time. The period of time required for pyrolyzing at least a portion of the precursor material may depend upon composition and / or structure of the precursor material and / or the desired structure of the carbon material. In some embodiments, the pyrolyzing of the activated precursor material is performed for a period of time (minutes) of about, or greater than about: 1, 2, 3, 4, 5, 10, 20, 30, 60, 120, 180, 240, 300, 360, 420, 480, 540, or 600. In some embodiments, the pyrolyzing of the activated precursor material is performed for a period of time (minutes) of less than about: 600, 540, 480, 420, 360, 300, 240, 180, 120, 60, 30, 20, 10, 5, 4, 3, 2, or 1. The period of time for which the pyrolyzing of the activated precursor material is performed of may be provided in a range provided by any two of these upper and / or lower values, for example, thepyrolyzing of the activated precursor is performed for a period of time (minutes) of: between about 1 to about 600, or between about 30 to about 540, or between about 30 to about 120.

[0117] This period of time may be carefully selected to either ensure the complete carbonization of the material or to regulate the form of salts or metals, thereby influencing the resulting porous structures.Optional cooling after pyrolyzing

[0118] In embodiments where the activated precursor material is pyrolyzed, the activated precursor material may be cooled to a second temperature after pyrolyzing. In some embodiments, the second temperature is a reaction temperature.

[0119] In some embodiments, cooling the activated precursor material to a second temperature is performed at a rate (°C / min) of about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, 4, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50. In some embodiments, cooling the activated precursor material to a second temperature is performed at a rate (°C / min) of less than about: 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, 4, 3, 2, 1 0.5, 0.4, 0.3, 0.2, or 0.1. The rate of cooling of the activated precursor material to a second temperature may be provided by any two of these upper and / or lower values, for example, cooling the activated precursor material to a second temperature is performed at a rate (°C / min) of between about 0.1 to about 50.

[0120] In some embodiments, cooling of the activated precursor material to a second temperature is performed for a period of time (minutes) of about, or greater than about: 1, 2, 3, 4, 5, 10, 20, 30, 60, 120, 180, 240, 300, 360, 420, 480, 540, or 600. In some embodiments, cooling the activated precursor material to a second temperature is performed for a period of time (minutes) ofless than about: 600, 540, 480, 420, 360, 300, 240, 180, 120, 60, 30, 20, 10, 5, 4, 3, 2, or 1. The period of time for which cooling of the activated precursor material to a second temperature is performed may be provided in a range provided by any two of these upper and / or lower values, for example, cooling of the activated precursor to a second temperature is performed for a period of time (minutes) of: between about 1 to about 600, or between about 30 to about 540, or between about 30 to about 120.Reaction conditions

[0121] The inventors of the present application have discovered that by controlling the composition of reactants and the reaction conditions the method described herein can produce a range of carbon materials with controlled pore size and / or structure. Introducing an active gas, which is a gas that is capable of reacting with carbon in the precursor material to form carbon monoxide and / or carbon dioxide, removes at last a portion of the carbon from the precursor material forming pores within the structure thereby forming the carbon material. The activating material may act a catalyst to facilitate the reaction between the active gas and the carbon of the precursor material.

[0122] The reacting of the activated precursor material with the active gas may be performed in any suitable reaction vessel, for example an oven or a furnace.

[0123] In some embodiments, the active gas reacts with at least a portion of the carbon in the pyrolyzed activated material at a reaction temperature. The reaction temperature required may depend upon composition of the precursor material and / or the desired structure of the carbon material. In some embodiments, the reaction of the activated precursor material and the active gas is performed at a reaction temperature (°C) of about, or greater than about: 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, or 1000. In some embodiments the reaction of the activated precursor material and the active gas is performed at a reaction temperature (°C) of less than about: 1000, 950, 900, 850, 800, 750, 700, 650, 600, 550, 500, 450, or 400. The temperature at which the reaction of the activated precursor material and the active gas is performed of may be provided in a range provided by any two of these upper and / or lower values, for example, the reaction of the activated precursor material and the active gas is performed at a reaction temperature (°C) of: between about 400 to about 1000, between about 450 to about 950, or between about 500 to about 900.

[0124] In some embodiments, where pyrolyzing the activated precursor material is required, the reaction temperature is the same as the pyrolyzing temperature.

[0125] In some embodiments, where pyrolyzing the activated precursor material is required, the reaction temperature is less than the pyrolyzing temperature.

[0126] Reacting the activated precursor material with an active gas may be performed for any suitable period of time. The period of time required for reacting at least a portion of the precursor material with the active gas may depend upon composition and / orstructure of the precursor material and / or the desired structure of the carbon material. In some embodiments, the reaction of the activated precursor material and the active gas is performed for a period of time (minutes) of about, or greater than about: 1, 2, 3, 4, 5, 10, 20, 30, 60, 120, 180, 240, 300, 360, 420, 480, 540, or 600. In some embodiments, the reaction of the activated precursor material and the active gas is performed for a period of time (minutes) of less than about: 600, 540, 480, 420, 360, 300, 240, 180, 120, 60, 30, 20, 10, 5, 4, 3, 2, or 1. The period of time for which the reaction of the activated precursor material and the active gas is performed of may be provided in a range provided by any two of these upper and / or lower values, for example, the reaction of the activated precursor material and the active gas is performed for a period of time (minutes) of: between about 1 to about 600, or between about 30 to about 540, or between about 30 to about 120.

[0127] The flow rate of the active gas may be controlled during the reaction to, amongst other things, remove reaction products, and / or control the rate of reaction. In some embodiments, the active gas is introduced at a flow rate (L / min STP per kg of activated precursor material) of about, or greater than about 0.01, 0.02, 0.03, 0.04, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20. In some embodiments, the active gas is introduced at a flow rate (L / min STP per kg of activated precursor material) of less than about 20, 19, 18, 17, 16, 15, 14, 13, 12, 11, 10, 5, 4, 3, 2, 1 0.5, 0.4, 0.3, 0.2, 0.1, 0.05, 0.04, 0.03, 0.02, or 0.01. The flow rate of the active gas may be provided by any two of these upper and / or lower values, for example, the active gas is introduced at a flow rate (L / min STP per kg of activated precursor material) of between about 0.01 to about 10, between about 0.1 to about 5, or between about 0.1 to about 1.

[0128] The flow rate of the active gas may be controlled during the reaction to, amongst other things, remove reaction products, and / or control the rate of reaction. In some embodiments, the active gas is introduced at a flow rate (L / min STP per kg of precursor material) of about, or greater than about 0.01, 0.02, 0.03, 0.04, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20. In some embodiments, the active gas is introduced at a flow rate (L / min STP per kg of precursor material) of less than about 20, 19, 18, 17, 16, 15, 14, 13, 12, 11, 10, 5, 4, 3, 2, 1 0.5, 0.4, 0.3, 0.2, 0.1, 0.05, 0.04, 0.03, 0.02, or 0.01. The flow rate of the active gas may be provided by any two of these upper and / or lower values, for example, the active gas is introduced at a flow rate (L / min STP per kg of precursor material) of between about 0.01 to about 10, between about 0.1 to about 5, or between about 0.1 to about 1.

[0129] In some embodiments, especially when in large scale, the reaction vessel can be firstly opened at a temperature (°C) of less than about 400, 300, 200, 100, 50 or 25, and let the air fully fill the vessel. In some embodiments, the activated precursor material can be taken out of the vessel or left inside. Then the vessel is closed and may be heated to a reaction temperature (°C) of about, or greater than about: 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, or 1000. The active gas or inert gas or a combination thereof, may be introduced during the process at a flow rate (L / min) of about, or greater than about 0.01, 0.02, 0.03, 0.04, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20. The reaction temperature may be provided by any two of these upper and / or lower values.

[0130] In some embodiments, the active gas is introduced with a third inert gas.

[0131] The ratio of active gas to third inert gas introduced may be controlled to achieve the desired rate of reaction and or removal of reaction products. In some embodiments the ratio of the active gas to the third inert gas (v / v) is about, or greater than about: 1 :50, 1 :40, 1 :30, 1 :20, 1 : 10, 1 :5, 1 : 1, 2: 1, 3: 1, 4: 1 5: 1, 6: 1, 7: 1, 8: 1, 9: 1, 10: 1, 15: 1, 20: 1, 25: 1, 30: 1, 35: 1, 40: 1, 45: 1, 50:1, or 100: 1. In some embodiments, the ratio of the active gas to the third inert gas (v / v) is less than about 100: 1, 50: 1, 45: 1, 40:1, 35:1 30: 1, 25: 1, 20: 1, 15: 1, 10: 1, 9:1, 8: 1, 7: 1, 6: 1, 5: 1, 4: 1, 3: 1, 2: 1, 1 : 1, 1 :5, 1 : 10, 1 :20, 1 :30, 1 :40, or 1 :50. The ratio of the active gas to the third inert gas (v / v) may be provided in a range provided by any two of these upper and / or lower values, for example, the ratio of the active gas to the third inert gas (v / v) is between about 1 :50 to between about 100: 1, or between about 1 :20 to between about 3: 1.

[0132] The flow rate of the third inert gas may be controlled during the reaction. In some embodiments, the third inert gas is introduced at a flow rate (L / min STP per kg of activated precursor material) of about, or greater than about 0.01, 0.02, 0.03, 0.04, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100. In some embodiments, the third inert gas is introduced at a flow rate (L / min STP per kg of activated precursor material) of less than about 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, 4, 3, 2, 1 0.5, 0.4, 0.3, 0.2, 0.1, 0.05, 0.04, 0.03, 0.02, or 0.01. The flow rate of the third inert gas may be provided by any two of these upper and / or lower values, for example, the third inert gas is introduced at a flow rate (L / min STP per kg of activated precursor material) of between about 0.01 to about 100, between about 1 to about 25, or between about 5 to about 25.

[0133] The flow rate of the third inert gas may be controlled during the reaction. In some embodiments, the third inert gas is introduced at a flow rate (L / min STP per kg of precursor material) of about, or greater than about 0.01, 0.02, 0.03, 0.04, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100. In some embodiments, the third inert gas is introduced at a flow rate (L / min STP per kg of precursor material) of less than about 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, 4, 3, 2, 1 0.5, 0.4, 0.3, 0.2, 0.1, 0.05, 0.04, 0.03, 0.02, or 0.01. The flow rate of the third inert gas may be provided by any two of these upper and / or lower values, for example, the third inert gas is introduced at a flow rate (L / min STP per kg of precursor material) of between about 0.01 to about 100, between about 1 to about 25, or between about 5 to about 25.

[0134] In some embodiments, the third inert gas is selected from nitrogen, argon, and combinations thereof. In some embodiments, the composition of the third inert gas is the same as the composition of the first inert gas. In some embodiments, the composition of the third inert gas is the same as the composition of the second inert gas. In some embodiments, the composition of the third inert gas is the same as the composition of the second inert gas and the composition of the first inert gas.

[0135] In some embodiments, the reaction is performed at a pressure (atm) of about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, or 10. In some embodiments, the reaction is performed at a pressure (atm) of less than about: 10, 9, 8, 7, 6, 5, 4, 3, 2, 1 0.5, 0.4, 0.3, 0.2, or 0.1. The pressure at which the reaction is performed may be provided by any two of these upper and / or lower values, for example, the reaction is performed at a pressure (atm) of between about 0.1 to about 10, between about 0.5 to about 5.

[0136] In some embodiments, wherein the activated precursor material is pyrolyzed prior to introducing the active gas, the amount of carbon material obtained (% w / w) relative to activated precursor material is about, or greater than about 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 96, 97, 98, 99, 99.5, or 99.9. In some embodiments, the amount of carbon material obtained (% w / w) relative to activated precursor material is less than about 99.9, 99.5, 99, 98, 97, 96, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, or 10. The amount of carbon material obtained (% w / w) relative to activated precursor material may be provided by any two of these upper and / or lower values, for example, the amount of carbon material obtained (% w / w) relative to activated precursor material is between about 30 to about 99.9.

[0137] In some embodiments, wherein the activated precursor material is not pyrolyzed prior to introducing the active gas, the amount of carbon material obtained (% w / w) relative to activated precursor material is about, or greater than about 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 96, 97, 98, 99, 99.5, or 99.9. In some embodiments, the amount of carbon material obtained (% w / w) relative to activated precursor material is less than about 99.9, 99.5, 99, 98, 97, 96, 95, 90, 85, 80, 75, 70, 65, 60, 55, or 50. The amount of carbon material obtained (% w / w) relative to activated precursor material may be provided by any two of these upper and / or lower values, for example, the amount of carbon material obtained (% w / w) relative to activated precursor material is between about 80 to about 99.9.

[0138] In some embodiments, the process described herein is repeated two or more times. In some embodiments, the process described herein comprises one or more cycles wherein each cycle comprises (i) contacting the precursor material with an activating material to form the activated precursor material, (ii) heating an activated precursor material comprising an activating material and a precursor material that comprises carbon to a first temperature, (iii) optionally, pyrolyzing at least a portion of the activated precursor material, and (iv) introducing an active gas to the activated precursor material to react with at least a portion of the carbon in the activated precursor material to form the carbon material comprising a plurality of pores. The inventors have discovered that further perform multiple cycles can yield a hierarchically porous carbon structure with both mesopores and macropores, and potentially additional microporosity, leading to improved surface area and tailored pore distribution. In some embodiments, the process comprises two or more cycles described herein. In some embodiments, the process comprises two cycles described herein. In some embodiments, the process comprises three cycles described herein.Washing the carbon material

[0139] In some embodiments, the carbon material is washed. Washing removes at least a portion of the activating material. Washing is performed using and suitable washing solvent, which is any solvent capable suspending or dissolving at least a portion of the activating material. In some embodiments, the washing solvent is selected from: water, ethanol, dilute hydrochloric acid and combinations thereof. In some embodiments, the washing solvent is water, optionally deionised water.

[0140] In some embodiments, after washing, the amount of activating material in the carbon material (% w / w) is about, or greater than about 0.0001, 0.001, 0.01, 0.02, 0.03,0.04, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, 4, or 5. In some embodiments, after washing, the amount of activating material in the carbon material (% w / w) is less than about 5, 4, 3, 2, 1 0.5, 0.4, 0.3, 0.2, 0.1, 0.05, 0.04, 0.03, 0.02, 0.01, 0.001, or 0.0001. The amount of activating material in the carbon material (% w / w) after washing may be provided by any two of these upper and / or lower values, for example, the amount of activating material in the carbon material (% w / w) is between about 0.0001 to about 5, between about 0.0001 to about 0.001.

[0141] In some embodiments, after washing the carbon material is substantially free of activating material.Drying the carbon material

[0142] In some embodiments, after washing the carbon material the carbon material is be dried. Drying is performed to remove at least a portion of the washing solvent from the carbon material. The drying temperature required may depend upon composition and / or structure of the carbon material and / or washing solvent used.

[0143] In some embodiments, after drying, the amount of washing solvent in the carbon material (% w / w) is about, or greater than about 0.0001, 0.001, 0.01, 0.02, 0.03, 0.04, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, 4, or 5. In some embodiments, after drying, the amount of washing solvent in the carbon material (% w / w) is less than about 5, 4, 3, 2, 1 0.5, 0.4, 0.3, 0.2, 0.1, 0.05, 0.04, 0.03, 0.02, 0.01, 0.001, or 0.0001. The amount of washing solvent in the carbon material (% w / w) after drying may be provided by any two of these upper and / or lower values, for example, the amount of washing solvent in the carbon material (% w / w) is between about 0.0001 to about 5, between about 0.0001 to about 0.001.

[0144] In some embodiments, after drying the carbon material is substantially free of washing solvent.Product

[0145] Disclosed herein is a carbon material. In some embodiments, there is provided a porous carbon material. In some embodiments, the porous carbon material comprises a plurality of micropores, mesopores and / or macropores.

[0146] Disclosed herein is a carbon material comprising a plurality of pores, when produced by a method as described herein.

[0147] Herein a carbon material comprising a plurality of pores may comprise pores on various different scales, for example on the micro, meso and / or macro scale.

[0148] In one embodiment at least a portion of the plurality of pores have a diameter of: less than about 2nm; about 2 to about 50 nm; greater than about 50 nm; or a combination thereof. In another embodiment, at least a first portion of the plurality of pores have a diameter of about 2 to about 50 nm; and at least a second portion of the plurality of pores have a diameter greater than about 50 nm. For example, the carbon materials may comprise a plurality of pores, wherein at least a portion of the pores have a diameter of (in nm) of about: 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, and mixtures thereof. The pores having a diameter of greater than about 50 nm may have a maximum diameter of (in nm) about, at least about, or greater than about: 500, 475, 450, 425, 400, 375, 350, 325, 300, 275, 250, 225, 200, 175, 150, 125, 100, 75or 50. In yet another embodiment, at least a first portion of the plurality of pores have a diameter of less than about 2 nm; at least a second portion of the plurality of pores have a diameter of about 2 to about 50 nm; and at least a third portion of the plurality of pores have a diameter greater than about 50 nm. The diameter distribution of pores less than 10 nm may be calculated based on N2 gas adsorption method (BET) based on density functional theory, and the diameter of pore larger than 10 nm may be measured through SEM image with image J software. At least 200 pores may be used to quantify diameter distribution.

[0149] In another embodiment, at least about: 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% of the plurality of pores have a diameter in a range of about 2 nm to about 50 nm.

[0150] In another embodiment, at least about: 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% of the plurality of pores have a diameter greater than about 50 nm, for example in a range of about 50 to about 500 nm.

[0151] The pores may be measured by any appropriate means. For example:• the pore volume may be measured by one or more of: gas adsorption and / or mercury porosimetry methods; or in line with one or more standards, optionally selected from: ASTM D4404-18, ASTM D8325-20, and / or ISO 15901-2:2022;• the depth of the pores may be measured by atomic force microscopy; and / or• the pore size distribution may be measure by one or more of: gas adsorption and / or mercury porosimetry methods; or in line with one or more standards, optionally selected from: ISO 15901-2:2022, ASTM D4607, and / or ISO 21340:2017 ASTM D2862-16.

[0152] In some embodiments, the carbon material has one or more of the following characteristics: a BET surface area (in m2 / g) of greater than about 500, 750, 1000 or 1500, wherein the specific surface area is calculated by the Brunauer-Emmett-Teller (BET) method; a bimodal pore size distribution comprising a first peak and a second peak, wherein a first peak is in the range of between about 1 nm to about 50 nm, and wherein the second peak is in the range of between about 50 nm to about 600 nm; between about 10 to 90 (% v / v) of pores with a pore size (in nm) of between about 1 to about 50, or between about 1 to 20; between about 10 to 90 (% v / v) of pores with a pore size (in nm) of between about 50 to about 600, or between about 65 to 200; a pore volume (in cm3 / g) of between about 0.5 to about 1.0, or between about 0.7 to about 0.9; an average pore depth (nm) of between about 10 to about 900, between about 200 to about 400, or between about 300 to about 400, wherein the depth of the pores may be measured by an AFM test. The depth may be considered as the minimum height in the pore topographic profile in respect to the average height surrounding the pore. an ID / IG ratio (i.e. level of disordered carbon) of more than about than 0.6, wherein the order degree ID and graphitization degree IG of porous carbon may be characterized by a Renishaw in Via™ Raman microscope with an excitation wavelength of 514 nm. Five random spots on each sample may be picked to calculate change in D / G ratios of samples; an electrical conductivity (in S / m) of between about 101to about 106, or between about 102to about 104, wherein the porous carbon may be dried and compressed in a cylinder between two metal plungers at compression pressures. The DC electrical conductivity may be measured at room temperature by a two-probe technique; a thickness (in nm) of between about 1 to about 100, or between about 2 to about 20, wherein the thickness of porous carbon may be measured through SEM imaging.a diameter (in pm) of between about 0.1 to about 200, or between about 10 to about 50; and / or a density (in kg / m3) of between about 0.1 to about 2.2, or between about 1.2 to about 1.5, wherein the density of samples may be measured by a two-column density measuring system, according to ASTM D1505-68.

[0153] In some embodiments, the carbon material has a BET surface area (in m2 / g) of greater than about 500, 550, 600, 650, 700, 750, 800, 850, 900, 1000, 1250, or 1500.

[0154] In some embodiments, the carbon material has a bimodal pore size distribution comprising a first peak and a second peak, wherein a first peak is in the range of between about 1 nm to about 50 nm, and wherein the second peak is in the range of between about 50 nm to about 600 nm

[0155] In some embodiments, the carbon material has between about 10 to 90 (% v / v) of pores with a pore size (in nm) of between about 1 to about 50, or between about 20 to 40.

[0156] In some embodiments, the carbon material has between about 10 to 90 (% v / v) of pores with a pore size (in nm) of between about 50 to about 600, or between about 65 to 200.

[0157] In some embodiments, the carbon material has a pore volume (in cm3 / g) of between about 0.5 to about 1.0, or between about 0.7 to about 0.9. The pore volume is calculated by the Brunauer-Emmett-Teller (BET) method.

[0158] In some embodiments, the carbon material has an average pore depth (nm) of between about 10 to about 900, between about 200 to about 400, or between about 300 to about 400.

[0159] In some embodiments, the carbon material has an ID / IG ratio (i.e. level of disordered carbon) of more than about than 0.6, for example between about 0.8 and about 1.2.

[0160] In some embodiments, the carbon material has an electrical conductivity (inS / m) of between about 101to about 106, or between about 102to about 104

[0161] In some embodiments, the carbon material has a diameter (in pm) of between about 0.1 to about 200, or between about 10 to about 50.

[0162] In some embodiments, the carbon material a density (in kg / m3) of between about 0.1 to about 2.2, or between about 1.2 to about 1.5.

[0163] In some embodiments, the carbon material is a carbon film. In some embodiments, the carbon film has a thickness (in nm) of between about 1 to about 100, or between about 2 to about 20.

[0164] In another aspect of the present disclosure, there is provide a carbon material obtained from the method of described herein. In some embodiments, there is provide a porous carbon material as described herein obtained from the method of described herein. In some embodiments, there is provide a carbon film as described herein obtained from the method of described herein.

[0165] In another aspect of the present disclosure, there is an article comprising or composed of the carbon material described herein. In some embodiments, there is an article comprising or composed of the carbon material obtained from the method described herein.Uses

[0166] In another aspect of the present disclosure, there is provided to the use of the carbon material as described here, or as obtained via a method disclosed herein. The use may be selected from, but not limited to: as an adsorbent, electrode material, catalyst support, in water purification filter, for example in bacteria interception, as an electrode, for example as a supercapacitor electrode, in electrocatalysis, for example for electrocatalysis CO2 reduction, carbon capture, electromagnetic wave adsorption, gas / chemical separation or capture, and mixtures thereof.

[0167] As an illustrative example, when utilizing cellulose-based materials, such as cotton as a precursor coated with sodium carbonate, a heating temperature of 500 °C followed by air injection at the same temperature results in the production of macropores with diameters ranging from 50 nm to 400 nm (Figure 4). Conversely, mesopores with diameters ranging from 10 nm to 50 nm dominate when the heating temperature is 900 °C, and the cooling temperature is set to 500 °C for air injection (Figure 1). More interconnected porous structures can be achieved with a heating temperature of 900 °C and an air injection temperature of 600 °C. Structures featuring both macropores and mesopores can be obtained by setting the heating temperature between about 600 °C and about 800 °C and injecting air during the cooling phase when the temperature reaches600 °C. In certain embodiments, the invention has observed that porous carbon produced using artificial fibre as a precursor tends to exhibit smaller dimensions than those derived from biomass materials.EXAMPLE EMBODIMENTS

[0168] The present disclosure may be defined by one or more of the following nonlimiting example embodiments.1. A method of forming a carbon material comprising a plurality of pores, the method comprising: heating an activated precursor material comprising an activating material and a precursor material that comprises carbon to a first temperature; optionally, pyrolyzing at least a portion of the activated precursor material; and introducing an active gas to the activated precursor material to react with at least a portion of the carbon in the activated precursor material to form the carbon material comprising a plurality of pores.2. The method of example embodiment 1, the method further comprising: cooling the pyrolyzed activated material to a predetermined temperature above the room temperature prior to the introduction of the active gas to form a meso-macro porous carbon material.3. The method of example embodiment or example embodiment 2, the method further comprising: injecting the active gas when the temperature reaches a predetermined temperature during the heating process to form an ultrathin graphene-like carbon or an ultrathin hollow carbon, wherein the active gas is or comprises steam or water.4. The method of example embodiment 1, wherein at least a portion of the plurality of pores have a diameter of: less than about 2 nm; about 2 to about 50 nm; greater than about 50 nm; or a combination thereof.5. The method of example embodiment 1, wherein at least a first portion of the plurality of pores have a diameter of about 2 to about 50 nm; and at least a second portion of the plurality of pores have a diameter greater than about 50 nm.6 The method of any one of the preceding example embodiments, wherein at least a portion of the activated precursor material is pyrolyzed.7. The method of any one of the preceding example embodiments, wherein the active gas is introduced at a temperature (°C) of between about 300 to about 900, between about 450 to about 750, or between about 500 to about 600.8. The method of any one of the preceding example embodiments, wherein at least a portion of the carbon material is in the form of an optionally porous: fibre, film, powder, or a combination thereof.9. The method of any one of the preceding example embodiments, wherein the method further comprises at least one of: contacting a precursor material with an activating material to form the activated precursor material; cooling the pyrolyzed activated material prior to introducing the active gas; drying the activated precursor material prior to heating; washing the carbon material; drying the porous carbon material after washing; or a combination thereof.10 The method of any one of the preceding example embodiments, where the method does not comprise the use of a templating agent, optionally selected from: silica, Zeolite, Ca2CCh, AI2O3, NaCl, ZnCh, Na2CCh, one or more surfactants, a polymer, optionally a thermally decomposed polymer, optionally selected from PS, PVA, PMMA, and / or PU, a block copolymer, and mixtures thereof.11. The method of any one of the preceding example embodiments, wherein the activated precursor material comprises between about 0.1% w / w to about 10% w / w of an activating material.12. The method of any one of the preceding example embodiments, wherein at least one precursor material is selected from: activated carbon, activated carbon fibre, high- performance carbon fibre, recycled carbon fibre, biochar, carbon black, graphene, graphite, coal, pitch, cotton, jute, bamboo, paper, wood, nutshell, coconut shell, coconut fibre (Coir), viscose fibre, polyacrylonitrile fibre, semi-synthetic fibres and combinations thereof.13. The method of any one of the preceding example embodiments, wherein at least one precursor material is selected from: natural fibres, optionally cotton, jute, bamboo and coconut fibre; semi-synthetic fibres; viscose fibre; activated carbon fibre; carbon fibres, and combinations thereof.14. The method of any one of the preceding example embodiments, wherein at least one precursor material is selected from: biomass, optionally biochar, paper, wood, nutshell or coconut shell; activated carbon; coal; pitch; and combinations thereof.15. The method of any one of the preceding example embodiments, wherein at least one precursor material is selected from: natural fibres, cotton, bamboo, coconut fibre and other hollow fibres, and combinations thereof.16. The method of any one of the preceding example embodiments, wherein the activating material comprises at least one metal selected from: an alkali metal, an alkali earth metal, a transition metal, and combinations thereof.17. The method of any one of the preceding example embodiments, wherein the activating material comprises at least one of: a salt of an alkali metal, an alkali earth metal, a transition metal, or a combination thereof.18. The method of any one of the preceding example embodiments, wherein at least one activating material is selected from: potassium carbonate, potassium hydroxide, sodium carbonate, sodium hydroxide, sodium bicarbonate, lithium hydroxide, potassium chloride, sodium chloride, lithium chloride, calcium chloride, potassium sulphate, iron sulphate, iron chloride, zinc chloride, nickel nitrate, cobalt nitrate, and combinations thereof.19 The method of any one of the preceding example embodiments, wherein the activating material comprises a salt of potassium, sodium or calcium.20. The method of any one of the preceding example embodiments, wherein the activating material comprises at least one of: potassium hydroxide, potassium carbonate, sodium hydroxide, sodium carbonate, sodium bicarbonate, calcium chloride, or a combination thereof.21. The method of any one of the preceding example embodiments, wherein the contacting the precursor material comprising carbon with the activating material is performed at a temperature (°C) of: between about 0 to about 100, between about 10 to about 50, or between about 20 to about 30.22. The method of any one of the preceding example embodiments, wherein the contacting the precursor material with the activating material is performed for a period of time (hours) of: between about 0.1 to about 240, between about 5 to about 120, or between about 24 to about 72.23. The method of any one of the preceding example embodiments, wherein the activating material is present in an activating solution prior to contacting with the precursor material.24. The method of example embodiment 23, wherein the activating solution is a homogeneous activating solution.25. The method of example embodiment 23 or example embodiment 24, wherein the activating solution is an aqueous activating solution.26. The method of any one of example embodiments 23 to 25, wherein the activating solution further comprises a surfactant.27. The method of any one of example embodiments 23 to 26, wherein the activating solution comprises between about 0.1% w / w to about 50% w / w of the activating material, or between about 0.1% w / w to about 20% w / w of the activating material.28. The method of any one of example embodiments 23 to 27, wherein the ratio of activating solution to precursor material (on a w / w basis) is between about 1 : 1 to between about 50: 1, or between about 5: 1 to between about 25: 1.29. The method of any one of the preceding example embodiments, wherein the drying of the activated precursor material is performed at a temperature (°C) of between about 20 to about 200, between about 40 to about 100, or between about 60 to about 80.30. The method of any one of the preceding example embodiments, wherein the drying of the activated precursor material is performed for a period of time (minutes) of between about 1 to about 600, or between about 30 to about 120.31. The method of any one of the preceding example embodiments, wherein the heating to the first temperature is performed in a substantially inert atmosphere.32. The method of example embodiment 31, wherein the substantially inert atmosphere comprises a first inert gas.33. The method of any one of the preceding example embodiments, wherein the heating to the first temperature is performed in the presence of a first inert gas.34. The method of any one of the preceding example embodiments, wherein the heating of the activated precursor material to the first temperature is performed at a rate (°C / min) of between about 0.1 to about 50.35. The method of any one of example embodiments 32 to 34, wherein the first inert gas is selected from nitrogen, argon, and combinations thereof.36. The method of any one of the preceding example embodiments, wherein the pyrolyzing is performed in a substantially inert atmosphere.37. The method of example embodiment 36, wherein the substantially inert atmosphere comprises a second inert gas.38. The method of any one of the preceding example embodiments, wherein the pyrolyzing is performed in the presence of a second inert gas.39. The method of example embodiment 36, wherein the second inert gas is the same as the first inert gas.40. The method of any one example embodiments 32 to 39, wherein the first inert gas is introduced at a flow rate (L / min) of between about 0.01 to about 100, or between about 5 to about 25.41. The method of any one of the preceding example embodiments, wherein the first temperature (°C) is between about 400 to about 1000, between about 450 to about 950, or between about 500 to about 900.42. The method of any one of the preceding example embodiments, wherein the pyrolyzing of the activated precursor material is performed for a period of time (minutes) of between about 1 to about 600.43. A carbon material comprising a plurality of pores, when produced by the method of any one of the preceding example embodiments.44. The carbon material of example embodiments 43, wherein at least a portion of the plurality of pores have a diameter of: about 2 to about 50 nm; greater than about 50 nm; or a combination thereof.45. The carbon material, wherein at least a first portion of the plurality of pores have a diameter of about 2 to about 50 nm; and at least a second portion of the plurality of pores have a diameter greater than about 50 nm.46. A carbon material comprising a plurality of mesopores and macropores, wherein the carbon material has one or more of: a BET surface area (in m2 / g) of greater than about 500, 750, 1000, or 1500; a bimodal pore size distribution comprising a first peak and a second peak, wherein a first peak is in the range of between about 1 nm to about 50 nm, and wherein the second peak is in the range of between about 50 nm to about 600 nm; between about 10 to 90 (% v / v) of pores have a pore size (in nm) of between about 1 to about 50, or between about 20 to 40;between about 10 to 90 (% v / v) of pores have a pore size (in nm) of between about 50 to about 600, or between about 65 to 200; a pore volume (in cm3 / g) of between about 0.5 to about 1.0, or between about 0.7 to about 0.9; an average pore depth (nm) of between about 10 to about 900, between about 200 to about 400, or between about 300 to about 400; an ID / IG ratio (i.e. level of disordered carbon) of more than about than 0.6, optionally in a range of about 0.8 to about 1.2; an electrical conductivity (in S / m) of between about 101to about 106, or between about 102to about 104; a thickness (in nm) of between about 1 to about 100, or between about 2 to about 20; a diameter (in pm) of between about 0.1 to about 200, or between about 10 to about 50; and a density (in kg / m3) of between about 0.1 to about 2.2, or between about 1.2 to about 1.5.47. An article comprising or composed of the carbon material of any one of example embodiments 43 to 46.48. Use of the carbon material of any one of example embodiments 43 to 46, as: an adsorbent, an absorbent, an electrode material, as a catalyst support, in water purification, in electrocatalysis, in supercapacitor, battery, carbon capture, electromagnetic wave absorption, gas / chemical separation and sensor.EXAMPLESExample 1: Mesopore and macropore carbon fibre from cotton

[0169] 20 g of cotton fabric was soaked into IL of 2% KOH aqueous solution for 12 hours. The soaked cotton fabric was taken out from the solution and then dried at 80 °C for 1 hour in an oven. The KOH treated cotton sample was pyrolyzed by heating to 900 °C (heat rate of 10 °C / min), under a nitrogen atmosphere with 1 L / min flow rate and held at 900 °C for 1 hour. The pyrolyzed treated cotton was allowed to cool to 500 °C andheld at this temperature for 1 hour. At the temperature of 500 °C, the nitrogen flow rate was reduced to 0.1 L / min, and air was injected into the furnace with 0.02 L / min simultaneously. After 1 hour, the air flow was stopped. The resulting material was left to in the furnace to cool to room temperature. Once at room temperature the sample was taken out and washed with water before being dried in an oven.

[0170] The characteristics of the obtained carbon material was investigated. It was observed that a porous carbon fibre had been formed. SEM images (Figure 1) revealed a highly interconnected porous structures on the surface of carbon fibre, and the pore diameter ranged from 10 nm to 100 nm (Figure 2). This sample showed a 1180 m2 / g of BET surface area and 0.59 cc / g of pore volume. AFM image showed a rough surface with a pore depth of around 350 nm on average.

[0171] In X-ray diffraction (XRD) spectra (Figure 3), two broad and low-intensity diffraction peaks at 29 = 22.3° and 29 = 43.8° were observed for the porous carbon fibre, which can be indexed to (002) and (101) spacing of graphitic carbon (JCPDS No. 75- 1621). The two peaks of porous carbon fibre were broader compared with conventional activated carbon, indicating a less ordered graphitic structure of porous carbon fibre. The Raman spectra of the porous carbon fibre, exhibiting defective D band (1355 cm'1) and graphitic G band (1600 cm'1) of carbon materials, respectively (Figure 3). The relative intensity ratio of D and G bands (ID / IG) suggests the degree of structural disorder with respect to a perfect graphitic structure. The ID / IG suggests that more caves and defect sites were introduced during the activation process, in good agreement with the XRD data.Example 2: Macropore-dominated carbon fibre

[0172] 20 g of cotton fabric was soaked into 1 L of 2% KOH aqueous solution for 12 hours. The cotton fabric was then taken out from the solution and dried at 80 °C for 1 hour in an oven. The treated cotton sample was pyrolyzed by heating to 500 °C (heat rate of 10 °C / min), under a nitrogen atmosphere with 1 L / min flow rate and held at that temperature for 1 hour before injecting air at the same temperature. The nitrogen flow rate was reduced to 0.1 L / min, and air was injected into the furnace with 0.02 L / min simultaneously. After 1 hour, the air flow was stopped. The resulting material was left to in the furnace to cool to room temperature. Once at room temperature the sample was taken out and washed with water before being dried in an oven. Figure 4 shows SEM images of the surface morphology of porous carbon fibre prepared according to Example 2.Example 3: Mesopore and macropore carbon fibre from cotton in large scale

[0173] 200 g of cotton fabric was soaked into 1 L of 2% K2CO3 aqueous solution for 12 hours. The soaked cotton fabric was taken out from the solution and then dried at 80 °C for 1 hour in an oven. The K2CO3 treated cotton sample was pyrolyzed by heating to 900 °C (heat rate of 10 °C / min), under a nitrogen atmosphere with 1 L / min flow rate and held at 900 °C for 1 hour. The pyrolyzed treated cotton was allowed to cool to 50 °C and was taken out from the furnace. Fresh air was blown into the furnace, and then the pyrolyzed treated cotton was put back into the furnace followed by heating back to the temperature of 500 °C (heat rate of 10 °C / min). After 1 hour, the resulting material was left to in the furnace to cool to room temperature. Once at room temperature the sample was taken out and washed with water before being dried in an oven. Figure 5 shows SEM images of the surface morphology of porous carbon fibre prepared according to Example 3.Example 4: Ultrathin graphene-like carbon fibre with a hollow structure

[0174] 10 g of cotton fabric was soaked into 1 L of 2% KOH aqueous solution for 12 hours. The cotton fabric was then dried at 80 °C for 1 hour in an oven. The treated cotton sample was pyrolyzed by heating to 900 °C (heat rate of 10 °C / min) under a nitrogen atmosphere with 0.5 L / min flow rate. During this process, before entering the tube furnace, the nitrogen passed through a 1 L closed bottle. When the temperature in the furnace reached 500 °C, 50 ml of water was injected into the sealed bottle. Nitrogen vapourised water and carried it into the tube furnace. The final temperature at 900 °C was held for 1 hour before cooled to room temperature. Once at room temperature the sample was taken out and washed with water before being dried in an oven. Figure 6 shows SEM images of the surface morphology of porous carbon fibre prepared according to Example 4.Example 5: Meso and macropore-dominated carbon from varied materials

[0175] 20 g of wastepaper activated carbon fibres and commercial high-strength carbon fibres were soaked into 1 L of 2% KOH aqueous solution for 6 hours, respectively. Those materials were then dried at 80 °C for 1 hour in an oven. The treated samples were pyrolyzed by heating to 800 °C (heat rate of 10 °C / min) under a nitrogen atmosphere with 1 L / min flow rate and held at that temperature for 1 hour before being left to cool to 500 °C and held the temperature for 1 hour. At the temperature of 500 °C, the nitrogen flow rate was reduced to 0.1 L / min, and air was injected into the furnace with 0.02 L / minsimultaneously. After 1 hour, the air flow was stopped. The resulting material was left to in the furnace to cool to room temperature. Once at room temperature the sample was taken out and washed with water before being dried in an oven. Figure 7 shows SEM images of the surface morphology of porous carbon fibre prepared according to Example 5, using wastepaper (left), activated carbon fibre (middle) and high-strength carbon fibre (right) as raw materials.Example 6: Meso and macropore-dominated carbon from varied materials

[0176] 20 g of cotton was soaked into IL of 2% KC1, K2SO4 and CaCh aqueous solution for 6 hours, respectively. Those materials were then taken out and died at 80 °C for 1 hour in an oven. The treated samples were pyrolyzed by heating to 800 °C (heat rate of 10 °C / min) under a nitrogen atmosphere with 1 L / min flow rate and held at that temperature for 1 hour before being left to cool to 500 °C and held the temperature for 1 hour. At the temperature of 500 °C, the nitrogen flow rate was reduced to 0.1 L / min, and air was injected into the furnace with 0.02 L / min simultaneously. After 1 hour, the air flow was stopped. The resulting material was left to in the furnace to cool to room temperature. Once at room temperature the sample was taken out and washed with water before being dried in an oven. Figure 8 shows SEM images of the surface morphology of porous carbon fibre prepared according to Example 6, using Potassium chloride (left), Potassium sulphate (middle) and calcium chloride (right) as the activating material.Example 6: Influence on air amount on pore formation

[0177] 20 g of cotton fabric was soaked into IL of 2% KOH aqueous solution for 12 hours. The soaked cotton fabric was taken out from the solution and then dried at 80 °C for 1 hour in an oven. The KOH treated cotton sample was pyrolyzed by heating to 700 °C (heat rate of 10 °C / min), under a nitrogen atmosphere with 1 L / min flow rate and held at 700 °C for 1 hour. The pyrolyzed treated cotton was allowed to cool to 500 °C and held at this temperature for 1 hour. At the temperature of 500 °C, the nitrogen flow rate was reduced to 0.1 L / min, and air was injected into the furnace with 0.01 L / min simultaneously. After 1 hour, the air flow was stopped. The resulting material was left to in the furnace to cool to room temperature. Once at room temperature the sample was taken out and washed with water before being dried in an oven. Same as the above steps, change the amount of air introduced by changing the flow rate to 0.02 and 0.04 L / min,respectively. Figure 9 shows SEM images of the surface morphology of porous carbon fibres prepared according to Example 6.Example 7: Influence of dwell time

[0178] 20 g of cotton fabric was soaked into 1 L of 2% KOH aqueous solution for 12 hours. The soaked cotton fabric was taken out from the solution and then dried at 80 °C for 1 hour in an oven. The KOH treated cotton sample was pyrolyzed by heating to 800 °C (heat rate of 10 °C / min), under a nitrogen atmosphere with 1 L / min flow rate and held at 800 °C for 1 hour. The pyrolyzed treated cotton was allowed to cool to 500 °C and held at this temperature for 1 hour. At the temperature of 500 °C, the nitrogen flow rate was reduced to 0.1 L / min, and air was injected into the furnace with 0.01 L / min simultaneously. After 1 hour, the air flow was stopped. The resulting material was left to in the furnace to cool to room temperature. Once at room temperature the sample was taken out and washed with water before being dried in an oven. Same as the above steps, change the amount of air introduced by changing the dwell time at 500 °C to 10 mins and 30 mins, respectively. Figure 10 shows SEM images of the surface morphology of porous carbon fibres prepared according to Example 7.Example 8: Influence of amount of activating material to precursor

[0179] 20 g of cotton fabric was soaked into 1 L of 2% KOH aqueous solution for 12 hours. The soaked cotton fabric was taken out from the solution and then dried at 80 °C for 1 hour in an oven. The KOH treated cotton sample was pyrolyzed by heating to 600 °C (heat rate of 10 °C / min), under a nitrogen atmosphere with 1 L / min flow rate and held at 600 °C for 1 hour. The pyrolyzed treated cotton was allowed to cool to 500 °C and held at this temperature for 1 hour. At the temperature of 500 °C, the nitrogen flow rate was reduced to 0.1 L / min, and air was injected into the furnace with 0.01 L / min simultaneously. After 1 hour, the air flow was stopped. The resulting material was left to in the furnace to cool to room temperature. Once at room temperature the sample was taken out and washed with water before being dried in an oven. Same as the above steps, change the amount of activating material by changing the concentration to 1% and 4%,respectively. Figure 11 shows SEM images of the surface morphology of porous carbon fibres prepared according to Example 8.Example 9: Water purification filter (Bacteria interception):

[0180] A porous carbon fibre (Example 1) was used as an adsorbent, and a surface modification was engineered so that it has a positive charge. Then the porous carbon fibre was converted into carbon filter paper. The results show good bacteria interception of water. The test was conducted by Xiamen Filtertech industrial corporation based on rigorous health and safety testing, under NSF / ANSI 42&58&372 standards. See Figure 12.Example 10: Supercapacitor flexible electrode

[0181] The porous carbon fibre fabric (Example 1) and carbon fibre film (example 4) with a dimension of 2 cm * 2 cm were used directly as the electrode of the supercapacitor, respectively. For device usage, two pieces of carbon fibre fabric / film with PVA-based electrolyte in between can assembled into a flexible capacitor. If a higher capacitance is requested, metal oxides, such as Fe2O3, MnCh, and CoO can be deposited or grown on the carbon film, which will further improve the performance by more than 50%.

[0182] For the fabrication of the all-solid sandwich-structured symmetrical porous carbon film-based supercapacitor, two pieces of carbon fabric / films were sandwiched with PVA and H2SO4 solid electrolyte. Then the supercapacitor was sealed and packed with Scotch tapes. See Figure 13.

[0183] The porous carbon fibre fabric (Example 1) showed above 200 F / g of capacitance with 10,000 cycles running. The ultrathin carbon film (Example 4) showed above 300 F / g of capacitance with 100,000 cycles running.

[0184] It will be appreciated by persons skilled in the art that under the premise of ensuring that the activating material is loaded onto the precursor, one exemplary aspect this technique (or different from other techniques) is the introduction of active gas and the timing of introduction of active gas (Figure 14). For example, for meso-macro porous carbon (Examples 1, 2 and 3), the introduction of active gas (air) is conducted after the completion of heating / pyrolyzing and cooling down to a temperature. With furtherreference to Example 4: Ultrathin graphene-like carbon, the introduction of active gas (steam) is conducted when the temperature of heating / pyrolyzing reaches above 500 °C (e.g. to form the ultrathin hollow carbon as shown in Fig 14).

[0185] It will be appreciated by persons skilled in the art that numerous variations and / or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims

1. A method of forming a carbon material comprising a plurality of pores, the method comprising:heating an activated precursor material comprising an activating material and a precursor material that comprises carbon to a first temperature;optionally, pyrolyzing at least a portion of the activated precursor material; andintroducing an active gas to the activated precursor material to react with at least a portion of the carbon in the activated precursor material to form the carbon material comprising a plurality of pores.

2. The method of claim 1, the method further comprising:cooling the pyrolyzed activated material to a predetermined temperature above the room temperature prior to the introduction of the active gas to form a meso-macro porous carbon material.

3. The method of claim 1 or claim 2, the method further comprising:introducing the active gas when the temperature reaches a predetermined temperature during the heating process to form an ultrathin graphene-like carbon or an ultrathin hollow carbon, wherein the active gas is or comprises steam or water.

4. The method of claim 1, wherein at least a portion of the plurality of pores have a diameter of: less than about 2 nm; about 2 to about 50 nm; greater than about 50 nm; or a combination thereof.

5. The method of claim 1, wherein at least a first portion of the plurality of pores have a diameter of about 2 to about 50 nm; and at least a second portion of the plurality of pores have a diameter greater than about 50 nm.6 The method of any one of the preceding claims, wherein at least a portion of the activated precursor material is pyrolyzed.

7. The method of any one of the preceding claims, wherein the active gas is introduced at a temperature (°C) of between about 300 to about 900, between about 450 to about 750, or between about 500 to about 600.

8. The method of any one of the preceding claims, wherein at least a portion of the carbon material is in the form of an optionally porous: fibre, film, powder, or a combination thereof.

9. The method of any one of the preceding claims, wherein the method further comprises at least one of:contacting a precursor material with an activating material to form the activated precursor material;cooling the pyrolyzed activated material prior to introducing the active gas;drying the activated precursor material prior to heating;washing the carbon material;drying the porous carbon material after washing; ora combination thereof.10 The method of any one of the preceding claims, where the method does not comprise the use of a templating agent, optionally selected from: silica, Zeolite, Ca2CO3, AI2O3, NaCl, ZnCh, Na2CO3, one or more surfactants, a polymer, optionally a thermally decomposed polymer, optionally selected from PS, PVA, PMMA, and / or PU, a block copolymer, and mixtures thereof.

11. The method of any one of the preceding claims, wherein the activated precursor material comprises between about 0.1% w / w to about 10% w / w of an activating material.

12. The method of any one of the preceding claims, wherein at least one precursor material is selected from: activated carbon, activated carbon fibre, high-performance carbon fibre, recycled carbon fibre, biochar, carbon black, graphene, graphite, coal, pitch, cotton, jute, bamboo, paper, wood, nutshell, coconut shell, coconut fibre (Coir), viscose fibre, polyacrylonitrile fibre, semi-synthetic fibres and combinations thereof.

13. The method of any one of the preceding claims, wherein at least one precursor material is selected from: natural fibres, optionally cotton, jute, bamboo and coconut fibre; semi-synthetic fibres; viscose fibre; activated carbon fibre; carbon fibres, and combinations thereof.

14. The method of any one of the preceding claims, wherein at least one precursor material is selected from: biomass, optionally biochar, paper, wood, nutshell or coconut shell; activated carbon; coal; pitch; and combinations thereof.

15. The method of any one of the preceding claims, wherein at least one precursor material is selected from: natural fibres, cotton, bamboo, coconut fibre and other hollow fibres, and combinations thereof.

16. The method of any one of the preceding claims, wherein the activating material comprises at least one metal selected from: an alkali metal, an alkali earth metal, a transition metal, and combinations thereof.

17. The method of any one of the preceding claims, wherein the activating material comprises at least one of: a salt of an alkali metal, an alkali earth metal, a transition metal, or a combination thereof.

18. The method of any one of the preceding claims, wherein at least one activating material is selected from: potassium carbonate, potassium hydroxide, sodium carbonate, sodium hydroxide, sodium bicarbonate, lithium hydroxide, potassium chloride, sodium chloride, lithium chloride, calcium chloride, potassium sulphate, iron sulphate, iron chloride, zinc chloride, nickel nitrate, cobalt nitrate, and combinations thereof.19 The method of any one of the preceding claims, wherein the activating material comprises a salt of potassium, sodium or calcium.

20. The method of any one of the preceding claims, wherein the activating material comprises at least one of: potassium hydroxide, potassium carbonate, sodium hydroxide, sodium carbonate, sodium bicarbonate, calcium chloride, or a combination thereof.

21. The method of any one of the preceding claims, wherein the contacting the precursor material comprising carbon with the activating material is performed at atemperature (°C) of: between about 0 to about 100, between about 10 to about 50, or between about 20 to about 30.

22. The method of any one of the preceding claims, wherein the contacting the precursor material with the activating material is performed for a period of time (hours) of: between about 0.1 to about 240, between about 5 to about 120, or between about 24 to about 72.

23. The method of any one of the preceding claims, wherein the activating material is present in an activating solution prior to contacting with the precursor material.

24. The method of claim 23, wherein the activating solution is a homogeneous activating solution.

25. The method of claim 23 or claim 24, wherein the activating solution is an aqueous activating solution.

26. The method of any one of claims 23 to 25, wherein the activating solution further comprises a surfactant.

27. The method of any one of claims 23 to 26, wherein the activating solution comprises between about 0.1% w / w to about 50% w / w of the activating material, or between about 0.1% w / w to about 20% w / w of the activating material.

28. The method of any one of claims 23 to 27, wherein the ratio of activating solution to precursor material (on a w / w basis) is between about 1:1 to between about 50:1, or between about 5:1 to between about 25:1.

29. The method of any one of the preceding claims, wherein the drying of the activated precursor material is performed at a temperature (°C) of between about 20 to about 200, between about 40 to about 100, or between about 60 to about 80.

30. The method of any one of the preceding claims, wherein the drying of the activated precursor material is performed for a period of time (minutes) of between about 1 to about 600, or between about 30 to about 120.

31. The method of any one of the preceding claims, wherein the heating to the first temperature is performed in a substantially inert atmosphere.

32. The method of claim 31, wherein the substantially inert atmosphere comprises a first inert gas.

33. The method of any one of the preceding claims, wherein the heating to the first temperature is performed in the presence of a first inert gas.

34. The method of any one of the preceding claims, wherein the heating of the activated precursor material to the first temperature is performed at a rate (°C / min) of between about 0.1 to about 50.

35. The method of any one of claims 32 to 34, wherein the first inert gas is selected from nitrogen, argon, and combinations thereof.

36. The method of any one of the preceding claims, wherein the pyrolyzing is performed in a substantially inert atmosphere.

37. The method of claim 36, wherein the substantially inert atmosphere comprises a second inert gas.

38. The method of any one of the preceding claims, wherein the pyrolyzing is performed in the presence of a second inert gas.

39. The method of claim 37 or claim 38, wherein the second inert gas is the same as the first inert gas.

40. The method of any one claims 32 to 39, wherein the first inert gas is introduced at a flow rate (L / min STP per kg of precursor material) of between about 0.01 to about 100, or between about 25 to about 5.

41. The method of any one of the preceding claims, wherein the first temperature (°C) is between about 400 to about 1000, between about 450 to about 950, or between about 500 to about 900.

42. The method of any one of the preceding claims, wherein the pyrolyzing of the activated precursor material is performed for a period of time (minutes) of between about 1 to about 600.

43. A carbon material comprising a plurality of pores, when produced by the method of any one of the preceding claims.

44. The carbon material of claims 43, wherein at least a portion of the plurality of pores have a diameter of: about 2 to about 50 nm; greater than about 50 nm; or a combination thereof.

45. The carbon material of claim 43, wherein at least a first portion of the plurality of pores have a diameter of about 2 to about 50 nm; and at least a second portion of the plurality of pores have a diameter greater than about 50 nm.

46. A carbon material comprising a plurality of mesopores and macropores, wherein the carbon material has one or more of:a BET surface area (in m2 / g) of greater than about 500, 750, 1000, or 1500;a bimodal pore size distribution comprising a first peak and a second peak, wherein a first peak is in the range of between about 1 nm to about 50 nm, and wherein the second peak is in the range of between about 50 nm to about 600 nm;between about 10 to 90 (% v / v) of pores have a pore size (in nm) of between about 1 to about 50, or between about 20 to 40;between about 10 to 90 (% v / v) of pores have a pore size (in nm) of between about 50 to about 600, or between about 65 to 200;a pore volume (in cm3 / g) of between about 0.5 to about 1.0, or between about 0.7 to about 0.9;an average pore depth (nm) of between about 10 to about 900, between about 200 to about 400, or between about 300 to about 400;an Id / Ig ratio (i.e. level of disordered carbon) of more than about than 0.6, optionally in a range of about 0.8 to about 1.2;an electrical conductivity (in S / m) of between about 101 to about 106, or between about 102 to about 104;a thickness (in nm) of between about 1 to about 100, or between about 2 to about 20;a diameter (in pm) of between about 0.1 to about 200, or between about 10 to about 50; anda density (in kg / m3) of between about 0.1 to about 2.2, or between about 1.2 to about 1.5.

47. An article comprising or composed of the carbon material of any one of claims 43 to 46.

48. Use of the carbon material of any one of claims 43 to 46, as: an adsorbent, an absorbent, an electrode material, as a catalyst support, in water purification, in electrocatalysis, in supercapacitor, battery, carbon capture, electromagnetic wave absorption, gas / chemical separation and sensor.

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