A carbonised carbon composition and an activated carbon and a method of producing a carbonised carbon composition and an activated carbon

Abstract

The present invention relates to a carbonised carbon composition comprising carbonised carbon, a binder and an alkali metal and / or alkali earth metal, and methods of producing the same. In particular, the present invention relates to a carbonised carbon composition comprising carbonised carbon, a binder and an alkali metal and / or alkali earth metal, wherein the binder is one or more sugars, and methods of producing the same. The present invention further relates to an activated carbon, and methods of producing the same.

Description

[0001] Title: A carbonised carbon composition and an activated carbon and a method of producing a carbonised carbon composition and an activated carbon

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to a carbonised carbon composition comprising carbonised carbon, a binder and an alkali metal and / or alkali earth metal, and methods of producing the same. In particular, the present invention relates to a carbonised carbon composition comprising carbonised carbon, a binder and an alkali metal and / or alkali earth metal, wherein the binder is one or more sugars, and methods of producing the same. The present invention further relates to an activated carbon, and methods of producing the same.

[0004] BACKGROUND OF THE INVENTION

[0005] Activated carbon has a high surface area owing to activated carbon being a highly porous material. Typically, activated carbon has a high surface area of greater than 400 m2 / g and a porosity of greater than 0.2 ml / g. This makes activated carbon a useful material in methane and hydrogen storage, purification such as air purification and water purification, solvent recovery, decaffeination, sewage treatment and many other applications.

[0006] Activated carbon is commonly used for the adsorption of various substances from liquids or gases. This adsorption of substance is particularly useful when using activated carbon for purification and / or filtration.

[0007] Activated carbon may additionally be used as a catalyst. Activated carbon is a particularly useful catalyst because activated carbon has a large specific surface area, pore structure and useful surface chemistry. Activated carbon is widely used as a catalyst in (a) the treatment of liquid and / or gases to promote the transformation of compounds such as, but not limited to, hydrogen peroxide, chloramines, chlorinated organic compounds, volatile organic compounds, chlorine and acid gases like hydrogen sulfide, and, (b) for the production of chemicals such as, but not limited to, phosgene and glyphosate. The impact of the surface chemistry of the activated carbon on its catalytic properties is well-recognised. The presence of certain oxygen and nitrogen functional groups on the surface of activated carbon is critical in this context.

[0008] The process for making activated carbon usually comprises two steps: pyrolysis (carbonization) followed by an activation step and is well known in the art, as exemplified in US5444031, US2013 / 0299748, US10518245, US2022 / 0340818, US2022 / 0352501 and US2023 / 0015387.

[0009] During pyrolysis, the carbon containing starting material is heated to temperatures of from 500 to 1100 °C in an oxygen deficient atmosphere. During this step, a gaseous intermediate product and a solid intermediate product are obtained. The gaseous intermediate product comprises light gasses and tar, and the solid intermediate product comprises char and solid by-products such as ashes. During the activation step, the solid intermediate product is either activated by exposure to a temperature of at least 800 °C in the presence of steam, or the solid intermediate product is chemically activated by exposure to chemicals such as, but not limited to, phosphoric acid. Chemical activation is typically carried out at temperatures lower than 800 °C. The final product, after activation, is called activated carbon.

[0010] A common starting material for making the solid intermediate product and activated carbon is a carbonaceous precursor. The carbonaceous precursor can be, but is not limited to, coconut shell, wood, coal and lignite. The adsorptive and catalytic properties of the resultant activated carbon can be impacted by the choice of carbonaceous precursor, and in particular the nitrogen content of the carbonaceous precursor. For example, a highly activated carbon can be produced if the carbonaceous precursor is rich in nitrogen. Typically, an activated carbon is understood to be “highly” activated when the activated carbon has a hydrogen peroxide decomposition rate parameter (T1 / 4) of less than 20 minutes.

[0011] To further control the catalytic properties of the resultant activated carbon, chemicals may be added during the pyrolysis or the activation step. For example, if an activated carbon has a low nitrogen content but the carbonaceous precursor and / or solid intermediate product are exposed to a nitrogen containing compound at a high temperature during the pyrolysis and / or activation, to increase the catalytic ability of the resultant activated carbon is increased. Typically, a high temperature in pyrolysis is considered to be a temperature of from 500 to 1100 °C and a high temperature in activation is considered to be at least 800 °C. Examples of nitrogen containing compounds that may be used include, but are not limited to, ammonia, urea and / or melamine.

[0012] Unfortunately, the use of nitrogen containing compounds has a number of disadvantages. Firstly, the use of nitrogen containing compounds elevates the overall cost of producing the activated carbon. Secondly, the use of nitrogen containing compounds also poses an environmental and safety hazard due to the potential production of toxic gaseous by-products such as NH3, NOXand hydrogen cyanide. Disadvantages such as these limit the overall usefulness of the resultant activated carbon.

[0013] There is therefore a need for the production of an improved activated carbon.

[0014] SUMMARY OF THE INVENTION

[0015] The present invention relates to a carbonised carbon composition comprising carbonised carbon, a binder and an alkali metal and / or alkali earth metal, and methods of producing the same. In particular, the present invention relates to a carbonised carbon composition comprising carbonised carbon and a binder and an alkali metal and / or alkali earth metal, wherein the binder is one or more sugars, and methods of producing the same. The present invention further relates to an activated carbon, and methods of producing the same.

[0016] The production of the carbonised carbon composition and activated carbon according to the present invention advantageously does not involve the use of unsafe or environmentally hazardous containing compounds. The activated carbon according to the present invention can be used in, but is not limited to, hydrogen peroxide decomposition, oxidative dehydrogenation of alkane and alkyl compounds, dehydration and dehydrogenation of alcohols, oxidation of acid gases such as NO, SOXand H2S, reduction of NO2and NOX, dehalogenation and dehydrohalogenation of organo-halogen compounds catalytic decomposition of ozone and catalytic wet air oxidation of phenol or pharmaceutical compounds.

[0017] Representative features of the present invention are set out in the following clauses, which stand alone or may be combined, in any combination, with one or more features disclosed in the text and / or figures of the specification.

[0018] The present invention is as set out in the following clauses:

[0019] 1 . A carbonised carbon composition, comprising: carbonised carbon, at least one binder; and at least one alkali metal and / or at least one alkali earth metal wherein the binder is one or more sugars.

[0020] 2. The carbonised carbon composition of clause 1 , wherein the at least one alkali metal and / or at least one alkali earth metal is potassium.

[0021] 3. The carbonised carbon composition of clause 1 or clause 2, wherein the one or more sugars is partially or completely inverted sugar.

[0022] 4. The carbonised carbon composition of any of clauses 1 to 3, wherein the one or more sugars is sourced from sugar cane molasses.

[0023] 5. The carbonised carbon composition of any of clauses 1 to 4, wherein the carbonised carbon is obtained from carbonising a carbonaceous precursor; optionally, wherein the carbonaceous precursor is MDF (medium-density fibreboard). 6. The carbonised carbon composition of any of clauses 1 to 5, wherein: the carbonised carbon is present at from 50 to 85, or, from 60 to 80, or, greater than 65, or, greater than 70, or, less than 80, or, less than 65 weight percentage of the total weight of the carbonised carbon composition; the binder is present at from 15 to 35, or, from 20 to 30, or, at 25 weight percentage of the total weight of the carbonised carbon composition; and / or the alkali metal and / or alkali earth metal is present at from 0.01 to 15, or, from 0.05 to 12, or, from 0.01 to 10 weight percentage of the total weight of the carbonised carbon composition.

[0024] 7. Activated carbon, comprising: nitrogen at from 0.50 to 5.0 weight percentage of the total weight of the activated carbon; carbon at from 70.00 to 95.00 weight percentage of the total weight of the activated carbon; hydrogen at from 0.00 to 1 .50 weight percentage of the total weight of the activated carbon; sulfur at from 0.00 to 1 .00 weight percentage of the total weight of the activated carbon; and / or oxygen at from 1 .00 to 6.00 weight percentage of the total weight of the activated carbon; any balance being unavoidable impurities.

[0025] 8. The activated carbon of clause 7, wherein the activated carbon comprises: nitrogen at from 1 .50 to 3.00, or, 1 .93 weight percentage of the total weight of the activated carbon; carbon at from 75.00 to 90.00, or, 84.19 weight percentage of the total weight of the activated carbon; hydrogen at from 0.20 to 1 .00, or, 0.46 weight percentage of the total weight of the activated carbon; sulfur at from 0.10 to 0.50, or, 0.17 weight percentage of the total weight of the activated carbon; and / or oxygen at from 3.50 to 5.50, or, 4.27 weight percentage of the total weight of the activated carbon; any balance being unavoidable impurities.

[0026] 9. The activated carbon of clause 7 or clause 8 wherein the activated carbon has a minimum hydrogen peroxide decomposition time (T1 / 4) of less than 90 minutes, or, less than 80 minutes, or, less than 70 minutes, or, less than 60 minutes, or, less than 50 minutes, or, less than 45 minutes, or, less than 40 minutes, or, less than 35 minutes, or, less than 30 minutes, or, less than 25 minutes, or, less than 20 minutes.

[0027] 10. The activated carbon of any of clauses 7 to 9, wherein the activated carbon has a surface area analysis (BET) of from 1500 m2 / g or less, or, from 1000 m2 / g or less, or, from 800 to 1000 m2 / g.

[0028] 11 . The activated carbon of any of clauses 7 to 10, wherein the activated carbon has an iodine number of less than 1500 mgh / g, or, less than 1000 mgh / g, or, less than 980 mgh / g, or, less than 975 mgh / g, or, from 700 to 1200 mgh / g, or, from 700 to 1100 mgh / g, or, from 764 to 1077 mgh / g.

[0029] 12. The activated carbon of any of clauses 7 to 11 , wherein the activated carbon (AC) has a methylene blue (MB) number of from 5 to 25 gMB / 100gAC, or, from 10 to 20 gMB / 100gAC, or, from 10.5 to 18.3 gMB / 100gAC.

[0030] 13. The activated carbon of any of clauses 7 to 12, wherein the activated carbon has an apparent density of from 200 to 650 kg / m3, or 300 to 550 kg / m3, or, from 400 to 550 kg / m3, or, from 419 to 458 kg / m3, or, from 358 to 458 kg / m3.

[0031] 14. The activated carbon of any of clauses 7 to 13, wherein the activated carbon has a ball pan hardness (BPH) of less than or equal to 98 %, or, less than or equal to 95 %, or, less than or equal to 90 %, or, from 70 to 95 %, or, from 85 to 90 %.

[0032] 15. The activated carbon of any of clauses 7 to 14, wherein the activated carbon is in the form of an extrudate, powder, granules and / or combinations thereof.

[0033] 16. A method of forming the carbonised carbon composition of any of clauses 1 to 6, the method comprising the steps of: (a) providing a carbonaceous precursor;

[0034] (b) subjecting the carbonaceous precursor to pyrolysis to form a solid intermediate product;

[0035] (c) providing a binder; and

[0036] (d) mixing the solid intermediate product with the binder to form the carbonised carbon composition.

[0037] 17. The method of clause 16, wherein the carbonaceous precursor in step (a) is MDF (medium density fibreboard).

[0038] 18. The method of clause 16 or clause 17, wherein the carbonaceous precursor undergoes pyrolysis in step (b) at a temperature of at least 500 °C, or, from 500 to 1100 °C, or, from 600 to 800 °C, or, at 750 °C.

[0039] 19. The method of any of clauses 16 to 18, wherein the carbonaceous precursor undergoes pyrolysis in step (b) for from 10 to 120 minutes, or, from 15 to 60 minutes, or, from 20 to 40 minutes, or, 30 minutes.

[0040] 20. The method of any of clauses 16 to 19, wherein the binder in step (c) is one or more sugars; optionally, wherein the one or more sugars is an inverted sugar; optionally, wherein the one or more sugars is sourced from sugar cane molasses.

[0041] 21 . The method of any of clauses 16 to 20, wherein the solid intermediate product and the binder are mixed in step (d) in the presence of water; optionally, wherein the ratio of binder, water and solid intermediate product is 30:30:100 of respectively.

[0042] 22. The method of any of clauses 16 to 21 , wherein the carbonised carbon composition undergoes pelletisation.

[0043] 23. A method of forming the activated carbon of any of clauses 7 to 15, the method comprising the steps of:

[0044] (a) to (d) of any of clauses 16 to 22; and

[0045] (e) subjecting the carbonised carbon composition from (d) to activation to form the activated carbon. 24. The method of clause 23, wherein the carbonised carbon composition undergoes activation in step (e) at a temperature of at least 800 °C, or, at least 900 °C, or, at least 950 °C, or, from 800 to 1100 °C, or, from 900 to 1100 °C, or, from 950 to 1100 °C.

[0046] 25. The method of clause 23 or clause 24, wherein the carbonised carbon composition undergoes activation in step (e) for from 10 to 120 minutes, or, from 15 to 60 minutes, or, from 20 to 40 minutes, or, 30 minutes.

[0047] 26. The method of any of clauses 23 to 25, wherein the carbonised carbon composition is exposed to steam during activation in step (e), wherein the ratio of steam to the carbonised carbon composition is from 1 :50 to 1 :1 , or, from 1 :30 to

[0048] 1 :20, or, 1 :25; optionally, wherein the steam is water.

[0049] 27. The method of any of clauses 23 to 26, wherein the activated carbon undergoes granulation or pulverisation.

[0050] 28. The activated carbon of any of clauses 7 to 15 for use as a catalytic chemical activity enhancer; optionally, wherein the chemical activity is hydrogen peroxide decomposition, oxidative dehydrogenation of alkane and alkyl compounds, dehydration and dehydration of alcohols, oxidation of acid gases such as nitrous oxides (NOx), sulfureous oxides (SOx), hydrogen sulfide (H2S) and mixtures thereof, dehalogenation and dehydrohalogenation of organo-halogen compounds, catalytic decomposition of ozone and / or catalytic wet air oxidation of phenol or pharmaceutical compounds.

[0051] DETAILED DESCRIPTION

[0052] Embodiments of the invention are described below with reference to the accompanying drawings. The accompanying drawings illustrate various embodiments of systems, methods, and embodiments of various other aspects of the disclosure. Any person with ordinary skills in the art will appreciate that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. It may be that in some examples one element may be designed as multiple elements or that multiple elements may be designed as one element. In some examples, an element shown as an internal component of one element may be implemented as an external component in another and vice versa. Furthermore, elements may not be drawn to scale. Nonlimiting and non-exhaustive descriptions are described with reference to the following drawings. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating principles.

[0053] Figure 1 is a schematic depicting the process of forming the activated carbon of the present invention according to Example 2.

[0054] Figure 2 shows images of powdered activated carbon (PAC), granular activated carbon (GAC) and extruded activated carbon (EAC).

[0055] Figure 3 shows images of powdered activated carbon (PAC) and extruded activated carbon (EAC).

[0056] Embodiments of the present disclosure will be described more fully hereinafter with reference to the accompanying drawings in which like numerals represent like elements throughout the several figures, and in which example embodiments are shown. Embodiments of the claims may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

[0057] The words "comprising," "having," "containing," and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Although any systems and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the preferred systems and methods are now described. Some of the terms used to describe the present invention are set out below:

[0058] “Activation” refers to the process of subjecting a carbonaceous material to physical and / or chemical activation. Physical activation includes exposing the carbonaceous material to a temperature of at least 800 °C. Chemical activation includes exposing the carbonaceous material to chemicals such as, but not limited to, phosphoric acid at temperatures less than 800 °C.

[0059] “Activated carbon” refers to a porous form of carbon that has a high surface area relative to non-activated carbon, wherein the surface of the activated carbon is characterised by microscopic pores. Typically, the high surface area of activated carbon is taken by those skilled in the art to be greater than 400 m2 / g. Typically, the porosity of activated carbon is taken by those skilled in the art to mean a porosity of greater than 0.2 ml / g. Activated carbon is usually produced by pyrolysis (carbonization) and activation, wherein activation is either physical (such as high temperatures) or chemical (such as exposure to phosphoric acid).

[0060] “Carbonised carbon” refers to a form of carbon that has undergone pyrolysis (carbonization).

[0061] “Extruded activated carbon” or “EAC” refers to activated carbon that has been extruded. Typically, the activated carbon has an average particle diameter of from 0.7 to 150 mm and a particle length of from 0.7 to 150 mm. In some examples, the EAC may have a honeycomb structure.

[0062] “Granular activated carbon” or “GAC” refers to activated carbon in granular form. Typically, the activated carbon has an average particle diameter of greater than 0.297 mm, or, from 0.60 to 2.36 mm (8 to 30 Mesh).

[0063] “Hydrogen peroxide decomposition rate parameter” or “T1 / 4” refers to the time taken for 25 percent conversion of hydrogen peroxide to oxygen and water.

[0064] “Inverted sugar” refers to a sugar syrup, wherein at least some of the sucrose present in the sugar syrup has undergone hydrolysis to form glucose and fructose. An equimolar mixture of glucose and fructose is formed. To form the inverted sugar, sucrose is hydrolyzed by exposure to an acid, such as citric acid (sourced from, for example, lemon juice) and heat. The optical rotation of inverted sugar is opposite to that of the original sugar. The use of inverted sugar in the formation of the activated carbon advantageously provides mechanical strength and abrasion resistance.

[0065] “Powdered activated carbon” or “PAC” refers to activated carbon in powder form. Typically, when the PAC is in the form of flakes, the PAC has an average particle diameter of 5 mm. Typically, when the PAC is in the form of a powder formed by milling, the PAC has an average particle diameter of less than 0.297 mm, or, less than 100 pm.

[0066] “Pyrolysis” refers to the heating of an organic material, such as carbonaceous precursors, in the absence of oxygen. Typically, heating occurs at temperatures of from 500 to 1100 °C.

[0067] “Sugar” refers to any carbohydrate having the general formula of Cn(H2O)n.

[0068] Examples of sugars include, but are not limited to, monosaccharides such as glucose, fructose and / or combinations thereof, and / or, disaccharides such as sucrose, lactose, maltose and / or combinations thereof.

[0069] “Surface of the activated carbon” refers to the layer of the activated carbon that is adjacent to the air, in other words the layer of the activated carbon that is at the airactivated carbon interface. The surface of the activated carbon has a thickness of 10 nm.

[0070] Carbonised carbon composition

[0071] In some examples of the present invention, a carbonised carbon composition is provided. The carbonised carbon composition preferably comprises carbonised carbon, at least one binder, and at least one alkali metal and / or at least one alkali earth metal.

[0072] In some examples of the present invention, the binder is tar. In some examples of the present invention, the binder is one or more sugars.

[0073] Optionally, one or more of the sugars is completely or partially inverted sugar(s).

[0074] Optionally, one or more of the sugars is monosaccharides, disaccharides, oligosaccharides and / or mixtures thereof. Further optionally, the one or more sugars is fructose, glucose, sucrose, maltose, lactose, dextrose, galactose and / or mixtures thereof.

[0075] Optionally, the one or more sugars is sourced from sugar cane molasses, sugar beet molasses, fruits (such as but not limited to mangoes, grapes, cherries, pears, canned pears, watermelons, bananas, avocados, raspberries, apples, coconuts, sweet peas, sweet com, peaches, mangoes, dates and oranges), vegetables (such as but not limited to carrots, beetroot, tomatoes and pumpkins), agave, com syrup, rice syrup, brown rice syrup, maple syrup, honey and / or mixtures thereof. Preferably, one or more of the sugars is sourced from sugar cane molasses.

[0076] In some examples of the present invention, the carbonised carbon composition comprises the one or more sugars at from 15 to 35, or, from 20 to 30, or, at 25 weight percentage of the total weight of the carbonised carbon composition.

[0077] In some examples of the present invention, the carbonised carbon is obtained from carbonising a carbonaceous precursor. Optionally, wherein the carbonaceous precursor is MDF (medium-density fibreboard), particle board, chipboard, melamine (urea) formaldehyde, polyacrylonitrile (PAN), grain products, fruit pits, palm fronds, nutshells, wood, coconut shell, peat, coir, lignite, coal, petroleum pitch and / or mixtures thereof. Preferably, the carbonaceous precursor is MDF.

[0078] In some examples of the present invention, the carbonised carbon composition comprises the carbonised carbon at from 50 to 85, or, from 60 to 80, or, greater than 65, or greater than 70, or, less than, or, less than 65 weight percentage of the total weight of the carbonised carbon composition. In some examples of the present invention, the binder is one or more sugars sourced from sugar cane molasses and the carbonised carbon is obtained from carbonising MDF.

[0079] In some examples of the present invention, the carbonised carbon composition further comprises at least one alkali metal and / or at least one alkali earth metal. Optionally, the at least one alkali metal and / or at least one alkali earth metal is potassium.

[0080] In some examples of the present invention, the at least one alkali metal and / or at least one alkali earth metal is sourced from the source of the binder, and / or, the source of the carbonised carbon, and / or, additive chemicals including, but not limited to, chloride, sulfate, carbonate and / or nitrate salts of the alkali metal and / or alkali earth metal, and / or, combinations thereof. Optionally, the at least one alkali metal and / or at least one alkali earth metal is sourced from sugar cane molasses and / or MDF.

[0081] In some examples of the present invention, the carbonised carbon composition comprises the alkali metal and / or at least one alkali earth metal at from 0.01 to 15, or, from 0.05 to 12, or, from 0.01 to 10 weight percentage of the total weight of the carbonised carbon composition.

[0082] In some examples of the present invention, the carbonised carbon composition comprises carbonised carbon, at least one binder that is tar and at least one alkali metal and / or at least one alkali earth metal that is potassium. Optionally, the carbonised carbon is MDF.

[0083] In some examples of the present invention, the carbonised carbon composition comprises carbonised carbon, at least one binder that is one or more sugars and at least one alkali metal and / or at least one alkali earth metal that is potassium.

[0084] Optionally, the carbonised carbon is MDF. Activated carbon

[0085] In some examples of the present invention, an activated carbon is provided.

[0086] In some examples of the present invention, the activated carbon comprises nitrogen at from 0.50 to 5.0 weight percentage of the total weight of the activated carbon, carbon at from 70.00 to 95.00 weight percentage of the total weight of the activated carbon, hydrogen at from 0.00 to 1 .50 weight percentage of the total weight of the activated carbon, sulfur at from 0.00 to 1 .00 weight percentage of the total weight of the activated carbon and oxygen at from 1 .00 to 6.00 weight percentage of the total weight of the activated carbon, any balance being unavoidable impurities.

[0087] Optionally, the activated carbon comprises nitrogen at from 1 .50 to 3.00 or, 1 .93 weight percentage of the total weight of the activated carbon. In some examples of the present invention, the activated carbon comprises carbon at from 75.00 to 90.00, or, 84.19 weight percentage of the total weight of the activated carbon. In some examples of the present invention, the activated carbon comprises hydrogen at from 0.20 to 1 .00, or, 0.46 weight percentage of the total weight of the activated carbon. In some examples of the present invention, the activated carbon comprises sulfur at from 0.10 to 0.50, or, 0.17 weight percentage of the total weight of the activated carbon. In some examples of the present invention, the activated carbon comprises oxygen at from 3.50 to 5.50, or, 4.27 weight percentage of the total weight of the activated carbon, any balance being unavoidable impurities.

[0088] Optionally, the activated carbon comprises nitrogen at 1 .93 weight percentage of the total weight of the activated carbon, carbon at 84.19 weight percentage of the total weight of the activated carbon, hydrogen at 0.46 weight percentage of the total weight of the activated carbon, sulfur at 0.17 weight percentage of the total weight of the activated carbon and oxygen at 4.27 weight percentage of the total weight of the activated carbon, any balance being unavoidable impurities.

[0089] Optionally, the activated carbon comprises nitrogen at from 1 .50 to 3.00, or, from 1 .59 to 1 .93 weight percentage of the total weight of the activated carbon. In some examples of the present invention, the activated carbon comprises carbon at from 75.00 to 95.00, or, from 84.19 to 90.52 weight percentage of the total weight of the activated carbon. In some examples of the present invention, the activated carbon comprises hydrogen at from 0.20 to 1.10, or, from 0.46 to 1.07 weight percentage of the total weight of the activated carbon. In some examples of the present invention, the activated carbon comprises sulfur at from 0.0 to 1 .0, or, from 0.0 to 0.80 weight percentage of the total weight of the activated carbon. In some examples of the present invention, the activated carbon comprises oxygen at from 1 .50 to 5.50, or, from 2.08 to 4.58 weight percentage of the total weight of the activated carbon, any balance being unavoidable impurities.

[0090] Optionally, the activated carbon comprises nitrogen at from 1 .59 to 1 .93 weight percentage of the total weight of the activated carbon, carbon at from 84.19 to 90.52 weight percentage of the total weight of the activated carbon, hydrogen at from 0.46 to 1 .07 weight percentage of the total weight of the activated carbon, sulfur at from 0.0 to 0.80 weight percentage of the total weight of the activated carbon and / or oxygen at from 2.08 to 4.58 weight percentage of the total weight of the activated carbon, any balance being unavoidable impurities.

[0091] In some examples of the present invention, the activated carbon has a minimum hydrogen peroxide decomposition time (T1 / 4) of less than 90 minutes, or, less than 80 minutes, or, less than 70 minutes, or, less than 60 minutes, or, less than 50 minutes, or, less than 45 minutes, or, less than 40 minutes, or, less than 35 minutes, or, less than 30 minutes, or, less than 25 minutes, or, less than 20 minutes.

[0092] In some examples of the present invention, the activated carbon has a surface area analysis (BET) of from 1500 m2 / g or less, or, from 1000 m2 / g or less, or, from 800 to 1000 m2 / g.

[0093] In some examples of the present invention, the activated carbon has a surface area analysis (BET) (argon) of from 1500 m2 / g or less, or, from 1000 m2 / g or less, or, from 700 to 1000 m2 / g, or, from 800 to 1000 m2 / g, or, from 800 to 900 m2 / g, or, from 848 to 849 m2 / g. In some examples of the present invention, the activated carbon has a surface area analysis (BET) (nitrogen) of from 1500 m2 / g or less, or, from 1000 m2 / g or less, or, from 700 to 1000 m2 / g, or, from 800 to 1000 m2 / g, or, from 735 to 964 m2 / g.

[0094] In some examples of the present invention, the activated carbon has a minimum iodine number (IN) of less than 1500 mgh / g, or, less than 1000 mgh / g, or, less than 980 mgh / g, or, less than 975 mgh / g, or, from 700 to 1200 mgh / g, or, from 700 to 1100 mgh / g, or, from 764 to 1077 mgh / g. Iodine number measures the degree of activation of the activated carbon by being linked to the total porosity of the activated carbon.

[0095] In some examples of the present invention, the activated carbon has a methylene blue (MB) number of from 5 to 25 gMB / 100g, or, from 10 to 20 gMB / 100g, or, from 10.5 to 18.3 gMB / 100g.

[0096] In some examples of the present invention, the activated carbon has a methylene blue (MB) number of from 5 to 25 gMB / 1 OOgAC, or, from 10 to 20 gMB / 1 OOgAC, or, from 11 .4 to 18.3 gMB / 1 OOgAC, wherein “MB” is the methylene blue and “AC” is the activated carbon.

[0097] In some examples of the present invention, the activated carbon has an apparent density of from 200 to 650 kg / m3, or 300 to 550 kg / m3, or, from 400 to 550 kg / m3, or, from 419 to 458 kg / m3, or, from 358 to 458 kg / m3.

[0098] In some examples of the present invention, the activated carbon has a ball pan hardness (BPH) of less than or equal to 98 %, or, less than or equal to 95 %, or, less than or equal to 90 %, or, from 70 to 95 %, or, from 85 to 90 %.

[0099] In some examples of the present invention, the surface of the activated carbon has a potassium concentration of from 0.5 to 3.0 (percentage at.), or, from 0.7 to 2.8 (percentage at.), or, from 0.8 to 2.6 (percentage at.), or, from 0.9 to 2.5 (percentage at.) relative to the total number of elements at the surface of the activated carbon. In some examples of the present invention, the surface of the activated carbon has a chlorine concentration of from 0.1 to 1.2 (percentage at.), or, from 0.3 to 1.5 (percentage at.), or, from 0.4 to 1.4 (percentage at.), or, from 0.5 to 1.2 (percentage at.) relative to the total number of elements at the surface of the activated carbon.

[0100] Optionally, the surface of the activated carbon has a chlorine concentration of from 0.5 to 1.2 (percentage at.) and a potassium concentration of from 0.9 to 2.5 (percentage at.) relative to the total number of elements at the surface of the activated carbon.

[0101] In some examples of the present invention, the activated carbon has a minimum monochloramine removal of from 34 or more catalytic removal percentage of monochloramine after ten minutes reaction, or, from 35 or more catalytic removal percentage of monochloramine after ten minutes reaction, or, from 35.5 or more catalytic removal percentage of monochloramine after ten minutes reaction, or, from 36 or more catalytic removal percentage of monochloramine after ten minutes reaction, or, from 34 to 65 catalytic removal percentage of monochloramine after ten minutes reaction, or, from 36.9 to 58.9 catalytic removal percentage of monochloramine after ten minutes reaction. Optionally, the activated carbon has a minimum monochloramine removal of from 36 or more catalytic removal percentage of monochloramine after ten minutes reaction when the surface of the activated carbon comprises from 0.5 to 1 .2 (% at.) chlorine and from 0.9 to 2.5 (% at.) potassium relative to the total number of elements at the surface of the activated carbon.

[0102] In some examples of the present invention, the activated carbon has an oxygen weight percentage of from 1.50 to 5.50 (percentage by wt.), or, from 1 .80 to 5.20 (percentage by wt.), or, from 2.00 to 4.80 (percentage by wt.), or, from 2.05 to 4.65 (percentage by wt.), or, from 2.08 to 4.58 (percentage by wt.) relative to the total weight of the activated carbon. The weight percentage of oxygen in the activated carbon can be determined by elemental analysis (for example, with a CHNSO analyser). In some examples of the present invention, the surface of the activated carbon comprises oxygen (0 1s at) from 0.1 to 20 (percentage at.), or, from 0.5 to 15 (percentage at.), or, from 2.0 to 12.5 (percentage at.), or, from 2.2 to 11 .8 (percentage at.) relative to the total number of elements at the surface of the activated carbon. Optionally, the oxygen in the surface of the activated carbon is present in one or more of oxides, carbonyls, esters, hydroxyls, ethers, phenols, adsorbed water and / or combinations thereof. The oxygen content of the activated carbon can be determined by x-ray photoelectron spectroscopy (XPS).

[0103] In some examples of the present invention, the activated carbon has a minimum hydrogen sulfide (H2S) removal of from 0.10 g / g or more, or, from 0.12 g / g or more, or, from 0.13 g / g or more, or, from 0.14 g / g or more, or, from 0.12 to 0.32 g / g, or, from 0.13 to 0.31 g / g, or, from 0.14 to 0.30 g / g, or, from 0.141 to 0.293 g / g of the activated carbon.

[0104] Optionally, the activated carbon has a hydrogen sulfide (H2S) removal of from 0.141 to 0.293 g / g of the activated carbon and the activated carbon has an oxygen concentration of from 2.08 to 4.58 (percentage by wt.) relative to the total weight of activated carbon and the surface of the activated carbon has an oxygen concentration (O 1s at) of from 2.2 to 11 .8 percentage at. relative to the total number of elements at the surface of the activated carbon.

[0105] In some examples of the present invention, the activated carbon has a sulfur dioxide (SO2) removal of from 0.11 to 0.25 g / g, or, from 0.13 to 0.22 g / g, or, from 0.14 to 0.21 g / g, or, from 0.147 to 0.201 g / g of the activated carbon.

[0106] In some examples of the present invention, the activated carbon is in the form of a powder (powdered activated carbon PAC), granules (granular activated carbon GAC), extrudate (extrudate activated carboned EAC), and / or, combinations thereof. Optionally, the PAC, GAC and / or EAC have spherical, cylindrical and / or irregular shape.

[0107] In some examples of the present invention the activated carbon has a spherical, cylindrical and / or irregular shape. Method of producing the carbonised carbon composition

[0108] In some examples of the present invention, the carbonised carbon composition is produced by a method that comprises the following steps:

[0109] (a) providing a carbonaceous precursor;

[0110] (b) subjecting the carbonaceous precursor to pyrolysis to form a solid intermediate product;

[0111] (c) providing a binder; and

[0112] (d) mixing the solid intermediate product with the binder to form the carbonised carbon composition.

[0113] In some examples, the carbonaceous precursor in step (a) is MDF (medium-density fibreboard), particle board, chipboard, melamine (urea) formaldehyde, polyacrylonitrile (PAN), grain products, fruit pits, palm fronds, nutshells, wood, coconut shell, peat, coir, lignite, coal, petroleum pitch and / or mixtures thereof. Preferably, the carbonaceous precursor is MDF.

[0114] In some examples of the present invention, the carbonaceous precursor undergoes pyrolysis in step (b) by being subjected to heat in the absence of oxygen in a first furnace. Optionally, the temperature of the heat is at least 500 °C, or, from 500 to 1100 °C, or, from 600 to 800 °C, or, at 750 °C. Optionally, the time of pyrolysis is from 10 to 120 minutes, or, from 15 to 60 minutes, or, from 20 to 40 minutes, or, 30 minutes. Preferably, the temperature of the heat is 750 °C and the time of pyrolysis is 30 minutes.

[0115] During the pyrolysis, a first waste gas and the solid intermediate product are formed.

[0116] Optionally, the first waste gas is evacuated from the first furnace by being evacuated through the solid intermediate product. By evacuating the first waste gas through the solid intermediate product, the solid intermediate product is loaded with nitrogen from the first waste gas thereby increasing the nitrogen content of the solid intermediate product. The first furnace may comprise a through-hole through which the first waste gas is evacuated. Optionally, the solid intermediate product is piled up in front of the through-hole prior to the first waste gas being evacuated. By piling the solid intermediate product in front of the through-hole of the first furnace, more of the solid intermediate product is exposed to the first waste gas as it is evacuated from the first furnace thereby increasing the nitrogen content of the solid intermediate product. Once the first waste gas has passed through the solid intermediate product, the first waste gas is evacuated from the first furnace and may be recuperated as a fuel gas in downstream processes.

[0117] In some examples of the present invention, the solid intermediate product is removed from the first furnace prior to mixing with the binder.

[0118] In some examples of the present invention, the solid intermediate product is milled so as to be in the form of a powder prior to mixing with the binder.

[0119] In some examples of the present invention, the binder in step (c) is one or more sugars. Optionally, the one or more sugars is partially or completely inverted sugar(s). Optionally, the one or more sugars is monosaccharides, disaccharides, oligosaccharides and / or mixtures thereof. Further optionally, the one or more sugars is fructose, glucose, sucrose, maltose, dextrose, galactose and / or mixtures thereof. Optionally, the one or more sugars is sourced from sugar cane molasses, sugar beet molasses, fruits (such as but not limited to mangoes, grapes, cherries, pears, canned pears, watermelons, bananas, avocados, raspberries, apples, coconuts, sweet peas, sweet com, peaches, mangoes, dates and oranges), vegetables (such as but not limited to carrots, beetroot, tomatoes and pumpkins), agave, com syrup, rice syrup, brown rice syrup, maple syrup, honey and / or mixtures thereof. Preferably, the one or more sugars is sourced from sugar cane molasses.

[0120] In some examples of the present invention, the solid intermediate product and binder are mixed in step (d) in the presence of water. Optionally, at a ratio of 30:30:100 of binder, water and activated carbon respectively. Upon mixing, the carbonised carbon composition is formed. In some examples of the present invention, the carbonised carbon composition is pelletised and / or granulised. Optionally, the carbonised carbon composition is pelletised by being passed through a pelletiser.

[0121] In some examples of the present invention, the carbonised carbon composition is baked. Optionally, the carbonised carbon composition is baked for from 10 to 120 minutes, or, from 20 to 60 minutes, or, 30 minutes. Optionally, the carbonised carbon composition is baked at steps until a final temperature is achieved. Optionally, the carbonised carbon composition is baked once, two times, three times, or, four times. Optionally, the carbonised carbon composition is first baked at steps until a temperature of from 250 to 750 °C, or, from 300 to 600 °C, or, at 350 °C is achieved. Optionally, the carbonised carbon composition is baked for a second time at steps until a final temperature of from 400 to 800 °C, or, from 500 to 700 °C, or at 600 °C is achieved.

[0122] Optionally, the carbonised carbon composition passes through a pelletiser and is then baked. Optionally, the carbonised carbon composition passes through a pelletiser and is then baked for 30 minutes and at steps until a final temperature of 350 °C is achieved and then baked again for 30 minutes and at steps until a final temperature of 600 °C is achieved.

[0123] Method of producing the activated carbon

[0124] In some examples of the present invention, the activated carbon is produced by a method that comprises the following steps:

[0125] (a) to (d) as set out above under the heading “Method of producing the carbonised carbon composition”; and

[0126] (e) subjecting the carbonised carbon composition from (d) to activation to form the activated carbon.

[0127] In some examples of the present invention, the carbonised carbon composition passes to a second furnace for activation. In some examples of the present invention, the carbonised carbon composition undergoes physical or chemical activation in step (e). Physical activation includes exposing the carbonised carbon composition to a temperature of at least 800 °C. Chemical activation includes exposing the carbonised carbon composition to chemicals such as, but not limited to, phosphoric acid at temperatures less than 800 °C. Preferably, the carbonised carbon composition undergoes physical activation.

[0128] In some examples of the present invention, the carbonised carbon composition undergoes activation in step (e) by being subjected to heat in the second furnace in step (e).

[0129] Optionally, the temperature of the heat is at least 800 °C, or, at least 900 °C, or, at least 950 °C, or, from 800 to 1100 °C, or, from 900 to 1100 °C, or, from 950 to 1100 °C. Optionally, the time of activation is from 10 to 120 minutes, or, from 15 to 60 minutes, or, from 20 to 40 minutes, or, 30 minutes. Optionally, the carbonised carbon composition is exposed to steam during activation, wherein the ratio of steam to the carbonised carbon composition is from 1 :50 to 1 : 1 , or, from 1 :30 to 1 :20, or, 1 :25. Optionally, the steam is water. Preferably, the temperature of the heat is 950 °C, the time of activation is 30 minutes and activation occurs in the presence of steam wherein the ratio of steam to the mixture is from 1 :25.

[0130] During the activation, a second waste gas and the activated carbon are formed. Optionally, the second waste gas is evacuated from the second furnace by being evacuated through the activated carbon. By evacuating the second waste gas through the activated carbon, the activated carbon is loaded with nitrogen from the second waste gas thereby increasing the nitrogen content of the activated carbon. The second furnace may comprise a through-hole through which the second waste gas is evacuated. Optionally, the activated carbon is piled up in front of the through- hole prior to the second waste gas being evacuated. By piling the activated carbon in front of the through-hole of the second furnace, more of the activated carbon is exposed to the second waste gas as it is evacuated from the second furnace thereby increasing the nitrogen content of the activated carbon. Once the second waste gas has passed through the activated carbon, the second waste gas is evacuated from the second furnace and may be recuperated as a fuel gas in downstream processes. In some examples of the present invention, the activated carbon is additionally exposed to an oxidizing gas during activation in step (e). The oxidizing gas may be carbon oxide (CO) and / or carbon dioxide (CO2).

[0131] In some examples of the present invention, the carbonaceous precursor, solid intermediate product, carbonised carbon composition and / or the activated carbon are moved through the first and / or second furnaces by using a plurality of rollers or any other suitable suspension system arranged such that the carbonaceous precursor, solid intermediate product, carbonised carbon composition and / or the activated carbon move continuously through the first and / or second furnace.

[0132] In some examples of the present invention, the first furnace is the second furnace.

[0133] In some examples of the present invention, the first furnace and / or the second furnace are rotary kilns.

[0134] In some examples of the present invention, the activated carbon is further baked. Optionally, the temperature of baking is from 200 to 750 °C, or, from 300 to 400 °C, or, 350 °C.

[0135] In some examples of the present invention, the activated carbon is further processed, such as pelletisation to obtain an extruded activated carbon (EAC) or granular activated carbon (GAC).

[0136] In some examples of the present invention, the activated carbon is further processed, such as pulverisation to obtain a powdered activated carbon (PAC). Optionally, pulverisation can be carried out by milling.

[0137] Uses of the activated carbon

[0138] In some examples of the present invention, the activated carbon is for use as a catalytic chemical activity enhancer. In particular, the activated carbon is for use as a catalytic chemical activity enhancer wherein the chemical activity is hydrogen peroxide decomposition, oxidative dehydrogenation of alkane and alkyl compounds, dehydration and dehydration of alcohols, oxidation of acid gases such as nitrous oxides (NOx), sulfureous oxides (SOx), hydrogen sulfide (H2S) and mixtures thereof, dehalogenation and dehydrohalogenation of organo-halogen compounds, catalytic decomposition of ozone and / or catalytic wet air oxidation of phenol or pharmaceutical compounds.

[0139] EXAMPLES

[0140] The following are non-limiting examples that discuss, with reference to tables and figures, the advantages of the present invention. The examples set forth herein are merely examples among other possible examples.

[0141] Example 1 : Forming comparative powdered activated carbon (PAC)

[0142] In this non-limiting example, six comparative powdered activated carbon (PAC) samples were formed. The PAC samples produced in this non-limiting example are comparative samples.

[0143] The PAC comparative samples were formed from four different carbonaceous precursors. The four different carbonaceous precursors were called “MDF HB”, “MDF F”, “MDF 0” and “MDF L1” and were sourced from three different suppliers of MDF. MDF HB sourced from Homanit, MDF F sourced from Foronex, MDF 0 sourced from Ortessa and MDF L1 sourced from llnilin.

[0144] The composition of the comparative PAC samples is set out in Table 1 . Table 1 : The composition of the comparative PAC samples according to the present invention.

[0145] All of the comparative PAC samples were produced separately by the same process. The process of producing the comparative PAC samples is set out below.

[0146] 1 . The carbonaceous precursor was added to an oven and heated at 750 °C for 30 minutes. Any oven can be used. In this non-limiting example, a Nabertherm rotary oven was used (model RSRC 120 1000 / 11 ). During the heating, the carbonaceous precursor underwent pyrolysis to form char flakes.

[0147] 2. The char flakes were retained in the oven.

[0148] 3. The char flakes were activated by heating the char flakes at 950 °C in the presence of steam for 30 minutes, wherein the ratio of char flakes to steam was 1 :25. During heating, the char flakes underwent activation to form activated char.

[0149] 4. The activated char was milled in a grinder to form activated char in the form of a powder. Any grinder can be used, in this non-limiting example a grinder from JM machines custom converted from a shredder machine type AM2018 / 200 was used.

[0150] PAC1 , PAC5 and PAC6 were produced from the same raw material. However, PAC1 , PAC5 and PAC6 were produced at different times and thus there may be slight variation in the properties of the activated carbon produced.

[0151] Example 2: Forming extrudate activated carbon (EAC) according to the present invention

[0152] In this non-limiting example, extruded activated carbon (EAC) samples, with some of the EAC samples according to the present invention, were formed. The EAC samples were formed from four different carbonaceous precursors. The source of the carbonaceous precursors is the same as for example 1 . A fifth activated carbon was used. The fifth activated carbon was obtained from Norit Nederland B.V. (“Norit RST3”) and is an activated carbon regularly used in the field of activated carbon. EAC6 is sourced in a form ready for use.

[0153] The carbonaceous precursors were combined with a binder, wherein the binder was sugar sourced from sugar cane molasses and sugar mixes. The sugar used in EAC1-4 and EAC9 is cane molasses 1 . Cane molasses 1-4 were sourced from sugar cane molasses. The providers of the sugar cane molasses are Tameco (cane molasses 1 ), Braumarkt (cane molasses 2), Guano Diffusion (cane molasses 3) and Temp Zen Global (cane molasses 4). Sugar mixes 1-8 were artificial sugar mixtures not sourced from sugar cane molasses. An EAC sample was made with the well- known binder, ammonium lignosulfonate, as a comparative example.

[0154] The composition of the EAC samples is set out in Table 2.

[0155] Table 2: The composition of the EAC samples according to the present invention. The composition of the sugar mix is set out in Table 3. The composition of the cane molasses is set out in Tables 4 and 5. The sugar provided the alkali earth and alkali metals.

[0156] Table 3: The composition of sugar mixes 1 to 8. Where “NA” is used, the information is not available.

[0157] Table 4: The approximate composition of the sugar (cane molasses 1 ) in samples EAC1 to EAC4 and EAC9.

[0158] “Approximate” refers to values provided by the supplier of the sugar (cane molasses 1 ) in a technical data sheet. Table 5: The experimental composition of cane molasses 1 to 4. Where “NA” is used, the information is not available.

[0159] “Experimental” refers to values obtained by the inventors when analysing the cane molasses.

[0160] All of the EAC samples were produced by the same method. The method of producing the EAC samples is set out below and is depicted in Figure 1.

[0161] 1 . The carbonaceous precursor was added to an oven and heated at 750 °C for 30 minutes. Any oven can be used. In this non-limiting example, a Nabertherm rotary oven was used (model RSRC 120 1000 / 11 ). Upon heating, the carbonaceous precursor underwent pyrolysis to forming char flakes.

[0162] 2. The char flakes were removed from the oven and milled in a grinder to form powdered char flakes. Any grinder can be used, in this non-limiting example a grinder from JM machines custom converted from a shredder machine type AM2018 / 200 was used.

[0163] 3. The powdered char flakes were mixed with the binder and water to form a mixture. For each sample, 30 g of binder and 30 g of water were added for every 100 g of powdered char flakes. Any mixer can be used. In this non- limiting example, a mixer from DOMO was used. Mixing was performed until a uniform mixture was formed.

[0164] 4. The mixture was extruded through a pelletiser to form extruded pellets. Any pelletiser can be used. In this non-limiting example, a flat die pellet mill (make KL 120C with 4 mm diameter mold) was used.

[0165] 5. The extruded pellets were placed in an oven and baked (a) for 30 minutes and at steps until a final temperature of 350 °C is achieved and then (b) for 30 minutes and at steps until a final temperature of 600 °C is achieved to form baked pellets. Any oven can be used. In this non-limiting example, a Nabertherm rotary oven was used (model RSRC 1201000 / 11 ).

[0166] 6. The baked pellets were retained in the oven and activated by heating the baked pellets at 950 °C in the presence of steam for 30 minutes, wherein the ratio of baked pellets to steam was 1 :25. During the heating, the baked pellets underwent activation to form activated pellets.

[0167] 7. The activated pellets underwent pelletisation to form extruded activated carbon (EAC) that comprised the activated carbon of the present invention. Any pelletiser can be used. In this non-limiting example, a flat die pellet mill (make KL 120C with 4 mm diameter mold) was used.

[0168] EAC6 is a product produced by Norit and came already made. EAC6 was therefore not produced by the above method.

[0169] Example 3: Forming granular activated carbon (GAC) according to the present invention

[0170] In this non-limiting example, a granular activated carbon (GAC) sample COC-L60- CAT was sourced from Carbon Activated Corp, Europe. The GAC sample is a catalytic coconut-shell based steam -activated carbon.

[0171] Table 6: The composition of the GAC sample according to the present invention. Example 4: Images of the powdered activated carbon (PAC), granular activated carbon (GAC) and extruded activated carbon (EAC)

[0172] In this non-limiting example, images of the activated carbon as a powdered activated carbon (PAC), granular activated carbon (GAC) and extruded activated carbon (EAC) were taken. The images can be obtained through the use of a camera. In this non-limiting example, a camera on a phone was used to obtain the images. The images of the activated carbon are shown in Figure 2.

[0173] Image (A) in Figure 2 shows powdered activated carbon (PAC) in the form of flakes. The diameter of the PAC is 5 mm.

[0174] Image (B) in Figure 2 shows powdered activated carbon (PAC) that was milled to form the PAC. The diameter of the PAC is less than 100 pm.

[0175] Image (C) in Figure 2 shows extruded activated carbon (EAC). The average diameter of the EAC is 4 mm and the length is from 2 to 8 mm.

[0176] Image (D) in Figure 2 shows granular activated carbon (GAC). The average diameter of the GAC is 8-30 Mesh (2.36 to 0.60 mm).

[0177] Example 5: Images of the powdered activated carbon (PAC) and extruded activated carbon (EAC)

[0178] In this non-limiting example, images of the activated carbon as a powdered activated carbon (PAC) and extruded activated carbon (EAC) were taken.

[0179] In this non-limiting example, the images were obtained by scanning electron microscopy (SEM). Before conducting the SEM analysis, each sample was affixed to an aluminium stub using a carbon adhesive. The pellets were oriented to show both longitudinal and cross-sectional views, ensuring that the powder was evenly spread across the surface of the stub. For the SEM examination, the samples were inserted into a JEOL JSM-6010PLUS / LV microscope, which is outfitted with an Ultirn Max 170 - X4 detector for Energy Dispersive X-ray Spectroscopy (EDS) analysis. The images of the activated carbon are shown in Figure 3.

[0180] Image (A) in Figure 3 shows extruded activated carbon (EAC).

[0181] Image (B) in Figure 3 shows powdered activated carbon (PAC).

[0182] Image (A) shows a variety of particles, wherein some of the particles have angular shapes and other particles have irregular shapes. Image (B) shows particles that are predominantly elongated and have a more defined geometric shape. Furthermore, the particles in image (A) are closely packed together and exhibit a coarse texture and a relatively consistent size distribution. In contrast, the particles in image (B) present a wider range of particle sizes, including some that are notably larger and more elongated, alongside smoother particles. It is suggested that the denser packing of the EAC, as opposed to the PAC, advantageously enhances catalytic efficiency. This is attributed to the more intimate interaction between the reactant, whether in gas or liquid form, and the carbon surface.

[0183] Images (A) and (B) in Figure 3 advantageously show that the activated carbon comprises a network of cracks. The porosity of the activated carbon can therefore be attributed to thermal stress within the carbon matrix of the activated carbon, rather than molecular re-arrangement within the carbon matrix.

[0184] Example 6: Measuring the catalytic activity of the powdered activated carbon (PAC) and extruded activated carbon (EAC) samples

[0185] In this non-limiting example, the catalytic activity of the PAC or the EAC samples from Examples 1 or 2 was measured. The catalytic activity was determined by measuring the hydrogen peroxide decomposition rate parameter (T1 / 4) for each sample.

[0186] The catalytic activity of the PAC or EAC samples was measured for each sample separately. Firstly, 150 mg of one of the PAC or EAC samples was dispersed in 100 ml deionized water and phosphate buffer solution (50 ml, 0.5 mol K2HPO4, 0.5 mol KH2PO4) to form a dispersion. The dispersion was then heated to 60°C in a water bath whilst stirring. Once the dispersion reached a temperature of 60°C, hydrogen peroxide (50 ml of 35% peroxide) was added to the dispersion. Addition of hydrogen peroxide started the decomposition reaction. The volume of oxygen that evolved as a function of time was measured to provide the hydrogen peroxide decomposition rate parameter (T1 / 4). In this non-limiting example, the hydrogen peroxide decomposition rate parameter was the time taken for 1 .75 m3of oxygen gas to be formed.

[0187] The volume of oxygen that evolved over time was measured by leading the oxygen formed though an outlet tube into a graduated 100 ml cylinder tube turned upside and filled with water. The oxygen pushed the water out of the cylinder. By switching the outlet tube to a second cylinder, volume measurement can be executed whilst noting the time of the switch. Switching the outlet tube between the two cylinders was done until a total sum of 1 .75 m3of oxygen was measured. The total time to reach 1 .75 m3of oxygen is the hydrogen peroxide decomposition time.

[0188] Table 7 shows the decomposition rate parameter (T1 / 4) for the PAC and EAC samples.

[0189] Table 7: The decomposition rate parameter (T1 / 4) for the PAC and EAC samples. In this non-limiting example, the concentration of potassium and chlorine relative to the number of elements on the surface of the activated carbon was also determined using x-ray photoelectron spectroscopy (XPS).

[0190] XPS is a method that indicates the elemental composition, atomic concentration, and electronic structure of materials. It is particularly sensitive to lithium and heavier elements. The process involves bombarding a sample with x-ray photons, which dislodge electrons from the inner shells of atoms from the top 10 nm of a material owing to electron interaction with other atoms. These electrons are then captured by a detector. The kinetic energy of the detected electrons is indicative of the binding energy of the electrons and is unique to each element. This allows for the identification of elements and their oxidation states within small energy ranges.

[0191] The XPS analysis was performed using a Thermo Scientific K-alpha XPS instrument with a 400pm spot size. The device operated in ultra-high vacuum conditions, maintaining a base pressure between 8E-08 and 2E-09 mbar. The device featured a monochromatic Al-K a x-ray source with an energy of 1486.68 eV. Both broad survey scans and detailed elemental scans were conducted, focusing on the 0 1s, C 1s, K2p, and Cl 2p regions, with pass energies set to 200 eV for survey scans and 50 eV for elemental scans.

[0192] Data analysis was carried out using Casa XPS software, version 2.3.23rev1 ,2K, against a Shirly background. The carbon-carbon double bond peak was modeled with an asymmetric line shape based on the Finite Lorentzian model, with a full-width half maximum (FWHM) between 0.6 and 1.1 eV. Other spectral features were modeled using a symmetric Gaussian-Lorentzian mix, with FWHMs between 1.2 and 2.0 eV. Comprehensive survey scans were executed across the full energy spectrum from 0 to 1350 eV to map the distribution of surface elements on the sample.

[0193] In this non-limiting example, the surface of the activated carbon was taken to be a layer adjacent to the air-activated carbon interface having a thickness of 10 nm. The concentration of potassium relative to the total number of elements at the surface of the activated carbon was called “K 2p” and the concentration of chlorine relative to the total number of elements at the surface of the active carbon was called “Cl 1s”.

[0194] The results are shown in Table 8.

[0195] Table 8: Concentration of potassium and chlorine of the activated carbon surface.

[0196] The values are shown as % at. relative to the total number of elements at the surface of the activated carbon.

[0197] From comparing PAC1 to PAC4 with EAC1 to EAC18 (respectively), the data in Table 7 clearly shows that for samples containing a binder, the decomposition rate parameter is considerably lower. This demonstrates that when the activated carbon is formed from a carbonised carbon composition that comprised a binder, the decomposition rate parameter is advantageously decreased.

[0198] From comparing the data for the EAC samples, the data in Table 7 clearly shows that for samples containing sugar as the binder, the decomposition rate parameter is considerably lower. This demonstrates that when the activated carbon is formed from a carbonised carbon composition that comprised sugar as the binder, the decomposition rate parameter is advantageously decreased compared to activated carbon formed from carbonised carbon and known binders.

[0199] Furthermore, from comparing the data for the EAC samples having sugar as the binder with EAC samples having unknown binders, the data in Table 7 clearly shows that for samples containing sugar as the binder, the rate parameter is considerably lower. This demonstrates that when activated carbon is formed from a carbonised carbon composition that comprised sugar as the binder, the decomposition rate parameter is, on the whole, decreased compared to that of a known activated carbon formed from carbonised carbon (without a binder). From comparing the data for activated carbon in the form of an EAC to activated carbon in the form of a PAC, activated carbon when in the form of an EAC can, on the whole, catalytically decompose the hydrogen peroxide faster than when activated carbon is in the form of a PAC.

[0200] The data shown in Table 8 indicates that when potassium and chlorine are present in the binder the decomposition rate parameter is reduced.

[0201] Example 7: Further characterising the activated carbon samples

[0202] In this non-limiting example, the EAC, PAC and GAC samples as made in Examples 1 and 2 and or as purchased in Example 3 were characterised by measuring the iodine number (IN), methylene blue number (MBN), apparent density ((pb), ball pan hardness (BPH) and specific surface area (SBET). Table 9 sets out the results of the characterisation.

[0203] The iodine number (IN) was measured using ASTM, according to ASTM D4607-14.

[0204] The methyl blue number (MBN) was measured using methylene blue in titration. The method of measuring the methyl blue number (MBN) followed the methyl blue capacity test standardised by the European Council of Chemical Manufacturers Federation (CEFIC).

[0205] The apparent density (pb) was measured using ASTM, according to ASTM D2854- 09.

[0206] The ball pan hardness (BPH) was measured using ASTM, according to ASTM 3802- 23.

[0207] The specific surface area (SBET) was measured by gas adsorption, using an ISO method, according to ISO 9277:10. Table 9: The iodine number, methylene blue number, apparent density, ball pan hardness and BET surface of the EAC, PAC and GAC samples.

[0208] Advantageously, EAC is made of activated carbon retained together by the addition of a binder. The carbonised carbon and binder undergo pelletisation to produce larger granules having typically spherical, cylindrical and / or irregular shape. The presence of the binder advantageously binds the carbonised carbon together to provide the desired mechanical strength and stability required for the granule to withstand the crushing and abrasion the granule is exposed to during activation and post activation (for example in transport). Activation advantageously forms free spaces in the granule.

[0209] Further advantageously, the use of a binder (such as one or more sugars) leads to the formation of a more disordered heterogeneous carbon matrix during the activation step. This advantageously results in surface exposure of functional groups and electron-rich centres, which cause the resultant activated carbon to have a high catalytic activity. Example 8: Measuring the elemental composition of the powder activated carbon

[0210] (PAC), extruded activated carbon (EAC) and granular activated carbon (GAC)

[0211] In this non-limiting example, the elemental composition of the EAC, PAC and GAC samples was measured.

[0212] The elemental composition of the samples was separately measured using a FlashEA 1112 CHNS / O Automatic Element Analyzer. For each sample, each sample was separately milled to a fine powder with a pestle and mortar. The fine powder was dried by heating in a lab furnace (in this non-limiting example the lab furnace was Hereaus T6030) at 130°C for three hours. The proportion of carbon (C), hydrogen (H), nitrogen (N) and sulfur (S) was measured in an element analyser for a first sample of the EAC sample. A second, fresh, sample of the same sample was then prepared in the same way and the proportion of oxygen (0) measured. The results are shown in Table 10.

[0213] Table 10: The elemental composition of the EAC, PAC and GAC samples from Examples 1 , 2 and 3. The data is shown as weight percentage of the total weight of the activated carbon.

[0214] If the weight percentage does not add to 100, then the remaining weight percentage is unavoidable impurities. Example 9: Measuring the catalytic removal of monochloramine of the powder activated carbon (PAC), extruded activated carbon (EAC) and granular activated carbon (GAC)

[0215] In this non limiting example, the catalytic removal of monochloramine (NH2CI) of the PAC, EAC and GAC samples from Examples 1 , 2 and 3 was measured.

[0216] To prepare the samples ready for measurement, each sample was firstly dried at a temperature of 130 °C for 3 hours and then milled so as to have a top cut of below 80 pm, wherein the top-cut refers to the 97 % of the particles that measure 80 pm or less in diameter after size classification.

[0217] To measure the catalytic removal of monochloramine (NH2CI), a 20 ppm monochloramine solution was prepared by mixing 0.028 M ammonium chloride with 01014 M sodium hypochlorite in a 4:1 vol / vol ratio. Then 400 g of the 20 ppm monochloramine solution was added to 200 mg of each EAC, PAC or GAC sample.

[0218] The catalytic degradation of monochloramine was guantified using UVA / IS spectrophotometry, monitoring the absorbance at a light wavelength of 515 nm after 10 minutes reaction. The guantification of monochloramine relies on the ability of monochloramine to produce a magenta-coloured compound when it reacts with N,N- diethyl-p-phenylenediamine, in the presence of a phosphate buffer and potassium iodide. The removal percentage of monochloramine after 10 minutes has been calculated using the following eguation:

[0219] [NH2Cl]Q- [NH2Cl]10x 100

[0220] [NH2CI]1Owith:

[0221] - [NH2Cl]o : the initial monochloramine concentration (20 ppm)

[0222] - [2CZ]io : the monochloramine concentration after 10 minutes catalytic removal reaction.

[0223] The results are shown in Table 11 . Table 11 : The catalytic removal percentage of monochloramine for the PAC, EAC and GAC samples after ten minutes reaction.

[0224] Table 11 shows that the EAC samples according to the present invention have a better rate of removing monochloramine compared to the PAC and GAC samples. Furthermore, by comparing Tables 7 and 10, the presence of potassium and chlorine in the activated carbon further improves monochloramine removal.

[0225] Example 10: Measuring the catalytic removal rate of hydrogen sulfide (H2S) of the extruded activated carbon (EAC) and granular activated carbon (GAC)

[0226] In this non limiting example, the catalytic removal of hydrogen sulfide of the EAC and GAC samples from Examples 1 , 2 and 3 was measured.

[0227] The catalytic removal of hydrogen sulfide of the EAC and GAC samples from Examples 1 , 2 and 3 was measured on an ASTM 6646-03. The ASTM 6646-03 determined the hydrogen sulfide (H2S) capacity of 116 ml of granular or extruded activated carbon contained within a column. Specifically, the ASTM 6646-03 determined the adsorption of a one volume percent of hydrogen sulfide (H2S) from a gas mixture containing 5% H2S and 95% moist air. The evaluation involved monitoring the time it took for the hydrogen sulfide (H2S) concentration at the column output to reach 50 ppm. The recorded time at which the concentration reached this threshold, known as the breakthrough time, was then used to calculate the volume of hydrogen sulfide (H2S) adsorbed per gram of activated carbon. Subsequently, this volume was then converted into the mass of hydrogen sulfide (H2S) using the known apparent density of the activated carbon according to the following equation: wherein, g AC is the hydrogen sulfide (H2S) adsorption capacity of the activated carbon per unit volume and pappis the apparent density of the activated carbon.

[0228] The hydrogen sulfide removal rate is shown in Table 12.

[0229] Table 12: The hydrogen sulfide removal rate of the EAC and GAC samples. The values are shown as g / g per the activated carbon (AC).

[0230] In this non-limiting example, the oxygen (0 1 s) concentration of the surface of the activated carbon was determined using x-ray photoelectron spectroscopy (XPS). In this non-limiting example, the surface of the activated carbon was taken to be the layer adjacent to the air-activated carbon interface having a thickness of 10 nm. The oxygen weight percentage is called “0” and the concentration of oxygen relative to the total number of elements at the surface of the active carbon is called “0 1s”. The 01 s signals were deconvoluted into five main groups: metal oxides at 530.0 ± 0.2 eV, C=O and O-C=O at 531.2 ± 0.1 eV, C-O-C and C-OH (aliphatic) at 532.5 ± 0.1 eV, phenolic at 533.8 ± 0.2 eV and absorbed water at 535.7 ± 0.4 eV. The results are shown in Table 13. Table 13: The weight percentage of total oxygen (0 % by wt.), the 0 1s oxygen concentration (at % relative to the total number of elements at the surface of the activated carbon) of the surface of the activated carbon and the concentration of the oxygen-containing functional groups (at. % relative to the total number of elements at the surface of the activated carbon) at the surface of the activated carbon for the

[0231] EAC samples

[0232] From Tables 12 and 13, it is apparent that the removal of hydrogen sulfide is related to the amount of oxygen present in the activated carbon.

[0233] Example 11 : Measuring the adsorption capacity of sulfur oxide (SO2) of the extruded activated carbon (EAC)

[0234] In this non-limiting example, the adsorption capacity of sulfur dioxide (SO2) of the extruded activated carbon (EAC) samples was measured. The method outlined in Example 10 was used. The data is shown in Table 14. Table 14: The catalytic removal rate of sulfur oxide (SO2) of the extruded activated carbon (EAC) samples. The values are shown as g / g per the activated carbon (AC).

[0235] The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilized for realizing the invention in diverse forms thereof.

[0236] Although certain example aspects of the invention have been described, the scope of the appended claims is not intended to be limited solely to these examples. The claims are to be construed literally, purposively, and / or to encompass equivalents.

Claims

CLAIMS1 . A carbonised carbon composition, comprising: carbonised carbon, at least one binder; and at least one alkali metal and / or at least one alkali earth metal wherein the binder is one or more sugars.

2. The carbonised carbon composition of claim 1 , wherein the at least one alkali metal and / or at least one alkali earth metal is potassium; and / or, wherein the one or more sugars is partially or completely inverted sugar.

3. The carbonised carbon composition of any of claim 1 or claim 2, wherein the one or more sugars is sourced from sugar cane molasses; and / or, wherein the carbonised carbon is obtained from carbonising a carbonaceous precursor; optionally, wherein the carbonaceous precursor is MDF (medium-density fibreboard).

4. The carbonised carbon composition of any of claims 1 to 3, wherein: the carbonised carbon is present at from 50 to 85, or, from 60 to 80, or, greater than 65, or, greater than 70, or, less than 80, or, less than 65 weight percentage of the total weight of the carbonised carbon composition; the binder is present at from 15 to 35, or, from 20 to 30, or, at 25 weight percentage of the total weight of the carbonised carbon composition; and / or the alkali metal and / or alkali earth metal is present at from 0.01 to 15, or, from 0.05 to 12, or, from 0.01 to 10 weight percentage of the total weight of the carbonised carbon composition.

5. Activated carbon, comprising: nitrogen at from 0.50 to 5.0 weight percentage of the total weight of the activated carbon;carbon at from 70.00 to 95.00 weight percentage of the total weight of the activated carbon; hydrogen at from 0.00 to 1 .50 weight percentage of the total weight of the activated carbon; sulfur at from 0.00 to 1 .00 weight percentage of the total weight of the activated carbon; and / or oxygen at from 1 .00 to 6.00 weight percentage of the total weight of the activated carbon; any balance being unavoidable impurities.

6. The activated carbon of claim 5, wherein the activated carbon comprises: nitrogen at from 1 .50 to 3.00, or, 1 .93 weight percentage of the total weight of the activated carbon; carbon at from 75.00 to 90.00, or, 84.19 weight percentage of the total weight of the activated carbon; hydrogen at from 0.20 to 1 .00, or, 0.46 weight percentage of the total weight of the activated carbon; sulfur at from 0.10 to 0.50, or, 0.17 weight percentage of the total weight of the activated carbon; and / or oxygen at from 3.50 to 5.50, or, 4.27 weight percentage of the total weight of the activated carbon; any balance being unavoidable impurities.

7. The activated carbon of claim 5 or claim 6 wherein the activated carbon has a minimum hydrogen peroxide decomposition time (T1 / 4) of less than 90 minutes, or, less than 80 minutes, or, less than 70 minutes, or, less than 60 minutes, or, less than 50 minutes, or, less than 45 minutes, or, less than 40 minutes, or, less than 35 minutes, or, less than 30 minutes, or, less than 25 minutes, or, less than 20 minutes; and / or, wherein the activated carbon has a surface area analysis (BET) of from 1500 m2 / g or less, or, from 1000 m2 / g or less, or, from 800 to 1000 m2 / g.

8. The activated carbon of any of claims 5 to 7, wherein the activated carbon has an iodine number of less than 1500 mgh / g, or, less than 1000 mgh / g, or, less than 980 mgh / g, or, less than 975 mgh / g, or, from 700 to 1200 mgh / g, or, from 700 to 1100 mgh / g, or, from 764 to 1077 mgh / g; and / or, wherein the activated carbon (AC) has a methylene blue (MB) number of from 5 to 25 gMB / 100gAC, or, from 10 to 20 gMB / 100gAC, or, from 10.5 to 18.3 gMB / 100gAC.

9. The activated carbon of any of claims 5 to 8, wherein the activated carbon has an apparent density of from 200 to 650 kg / m3, or 300 to 550 kg / m3, or, from 400 to 550 kg / m3, or, from 419 to 458 kg / m3, or, from 358 to 458 kg / m3; and / or, wherein the activated carbon has a ball pan hardness (BPH) of less than or equal to 98 %, or, less than or equal to 95 %, or, less than or equal to 90 %, or, from 70 to 95 %, or, from 85 to 90 %.

10. The activated carbon of any of claims 5 to 9, wherein the activated carbon is in the form of an extrudate, powder, granules and / or combinations thereof.

11. A method of forming the carbonised carbon composition of any of claims 1 to 4, the method comprising the steps of:(a) providing a carbonaceous precursor;(b) subjecting the carbonaceous precursor to pyrolysis to form a solid intermediate product;(c) providing a binder; and(d) mixing the solid intermediate product with the binder to form the carbonised carbon composition.

12. The method of claim 11 , wherein the carbonaceous precursor in step (a) is MDF (medium density fibreboard); and / or, wherein the carbonaceous precursor undergoes pyrolysis in step (b) at a temperature of at least 500 °C, or, from 500 to 1100 °C, or, from 600 to 800 °C, or, at 750 °C; and / or,wherein the carbonaceous precursor undergoes pyrolysis in step (b) for from 10 to 120 minutes, or, from 15 to 60 minutes, or, from 20 to 40 minutes, or, 30 minutes; and / or, wherein the binder in step (c) is one or more sugars; optionally, wherein the one or more sugars is an inverted sugar; optionally, wherein the one or more sugars is sourced from sugar cane molasses; and / or, wherein the solid intermediate product and the binder are mixed in step (d) in the presence of water; optionally, wherein the ratio of binder, water and solid intermediate product is 30:30:100 of respectively; and / or, wherein the carbonised carbon composition undergoes pelletisation.

13. A method of forming the activated carbon of any of claims 5 to 10, the method comprising the steps of:(a) to (d) of claim 11 or claim 12; and(e) subjecting the carbonised carbon composition from (d) to activation to form the activated carbon.

14. The method of claim 13, wherein the carbonised carbon composition undergoes activation in step (e) at a temperature of at least 800 °C, or, at least 900 °C, or, at least 950 °C, or, from 800 to 1100 °C, or, from 900 to 1100 °C, or, from 950 to 1100 °C; and / or, wherein the carbonised carbon composition undergoes activation in step (e) for from 10 to 120 minutes, or, from 15 to 60 minutes, or, from 20 to 40 minutes, or, 30 minutes; and / or, wherein the carbonised carbon composition is exposed to steam during activation in step (e), wherein the ratio of steam to the carbonised carbon composition is from 1 :50 to 1 :1 , or, from 1 :30 to 1 :20, or, 1 :25; optionally, wherein the steam is water; and / or,wherein the activated carbon undergoes granulation or pulverisation.

15. The activated carbon of any of claims 5 to 10 for use as a catalytic chemical activity enhancer; optionally, wherein the chemical activity is hydrogen peroxide decomposition, oxidative dehydrogenation of alkane and alkyl compounds, dehydration and dehydration of alcohols, oxidation of acid gases such as nitrous oxides (NOx), sulfureous oxides (SOx), hydrogen sulfide (H2S) and mixtures thereof, dehalogenation and dehydrohalogenation of organo-halogen compounds, catalytic decomposition of ozone and / or catalytic wet air oxidation of phenol or pharmaceutical compounds.

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