Formation and development of micropores in carbon prepared via catalytic carbonization of phenolic resin containing Fe or Ni compounds

The formation and development of micropores in carbon prepared by catalytic carbonization (graphitization) was investigated. Phenolic resin mixed with ferrocene or nickelocene was carbonized at 1000 °C in Ar. A novel mechanical method that was used for mixing phenolic resin and metallic compound favored formation of micropores in the resulting carbon, compared with conventional homogeneous mixing. Decreasing the catalyst content led to increased micropore surface area. At low catalyst content, catalyst particles were finely dispersed. Small (<10 nm) catalyst particles inhibited the development of stacked structures of carbon aromatic layers in the amorphous component (A-component), which in turn produced accessible micropores. Increasing catalyst content facilitated conversion of A-component into turbostratic component (Ts-component) with a partially graphitized structure, which decreased the number of micropores. The formation of Ts-component is related to the formation of mesopores, which progressively replaced micropores as the amount of Ts-component increased.

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► Catalytic carbonization (graphitization) of Fe- or Ni-containing phenolic resin.
► Mechanical mixing of phenolic resin and catalyst favors development of micropores.
► Micropores increase in number with decreasing catalyst content.
► Micropores are formed by inhibition of structure development of amorphous carbon.
► Micropores are replaced by mesopores with catalytic formation of graphitic layers.