Process for producing highly activated carbonaceous products

In a single-pass, self-sustaining, continuous process for the production of an activated carbonaceous product having a surface area of about 600 to 900 square meters per gram, the steps comprising:

• (a) introducing to the top of a vertical reactor a feed material containing less than about 10 percent by weight of moisture, and capable of thermal decomposition to a gaseous component and a solid activated carbonaceous product;
• (b) substantially continuously moving said material, as a packed bed and at a predetermined rate, downwardly through and outwardly from the bottom of said reactor, while withdrawing gases upwardly therethrough and offgases outwardly therefrom;
• (c) injecting air into said bed at least at three levels which are vertically spaced from one another and from said top and bottom of said reactor, to establish a primary activation zone at least one foot in depth, said air being injected at said levels at significantly different rates independently controlled so as to distribute it, and to thereby render said primary zone substantially isothermal, with said material therein having a substantially uniform temperature of about 1600.degree. to about 1800.degree. Fahrenheit, the combined rate of air injection being less than one pound of air per pound of said feed material, on a moisture-free basis;
• (d) injecting low temperature steam, in the substantial absence of oxygen, into said bed at a location spaced downwardly from said primary zone and at a rate of about 0.025 to 0.2 pound per pound of said feed material, on a moisture-free basis, to establish a secondary activation zone of substantial depth below said primary zone, said steam being injected at a rate just adequate to transport sufficient thermal energy from said secondary activation zone to the top of said bed for drying and thermal decomposition of said material, to produce a temperature of about 250.degree. to 600.degree. Fahrenheit in said off-gases and to cool said material exiting from said secondary zone to a temperature of about 200.degree. to 1500.degree. Fahrenheit, said material having an average residence time in said primary activation zone of about three to 90 minutes, and said exiting material comprising a substantially dry activated carbonaceous product having a surface area of about 600 to 900 square meters per gram.