Activated carbon and the method of making it
United States Patent [1 1 Zall [ Apr. 8, 1975 1 1 ACTIVATED CARBON AND THE METHOD OF MAKING IT [76] Inventor: David M. Zall, 10 N. Southwood Ave., Annapolis, Md. 21401 [22] Filed: Aug. 24, 1971 211 Appl. No.: 174,544  
 [52] US. Cl 117/62; 117/121; 117/169 R; 1l7/D1G. 11; 210/39; 210/40; 252/422; 252/425 [51] Int. Cl B44d 1/44 [58] Field of Search..... 117/100 B, 169 R. DIG. 11, 117/62, 47 R; 210/39, 40; 252/422, 425; 23/209 R, 209.9; 423/460 [56] References Cited UNlTED STATES PATENTS 2,029,962 2/1936 Urbain et a1. 210/40 X 2,292,199 8/1942 Carter 117/100 X 2,685,541 8/1954 Woodburn, Jr. et a1 117/169 R 2.739.912 3/1956 Smisko 117/228 3.006.783 10/1961 Haaijman et a1 117/169 X 3.387.941 6/1968 Murphy 23/2099 3,627,570 12/1971 Cass .1 1l7/D1G. 11  
 Primary Examiner-William D. Martin Assistant Examiner-Dennis C. Konopacki Attorney, Agent, or Firnz-R. S. Sciascia; Q. E. Hodges [57] ABSTRACT 3 Claims, N0 Drawings ACTIVATED CARBON AND THE METHOD OF MAKING IT BACKGROUND OF THE INVENTION Activated carbon is well known as a filtration medium in the treatment of sewage for clarification and removal of undesirable solids that may pollute drinking water. These activated carbons remove solids but do not remove the phosphates which are detrimental to the ecology.  
  To solve this problem a chemical process has been found that can activate carbon to remove phosphates from the effluent.  
 SUMMARY OF THE INVENTION The invention is a chemical process for activating carbon and for removal of phosphates by introducing cations from at least one of the following metals: aluminum, manganese, magnesium, zinc, iron, lithium, or calcium, into the carbon; said cations having the ability to combine with the phosphate to form an insoluble phosphate that can be retained by the carbon.  
 OBJECTS OF THE INVENTION DESCRIPTION OF THE PREFERRED EMBODIMENT Removal of phosphates from waste effluents is a major objective in water purification. Activated carbon has been used in the past to filter solids but the activated carbon has not been capable of removing phosphates from the effluent. To remedy this situation a method has been found for activating carbon for that particular purpose. The treatment consists of saturating the carbon with a solution of either aluminum chloride, zinc chloride, magnanese chloride, magnesium chloride, calcium chloride, or iron chloride. Chloride solutions are used to obviate the introduction of any undesirable chemicals into the effluent. It would be within the scope of the invention, however, to use nitrates or sulfates as impregnates for activating the carbon. Later in the process however, the carbon is treated with sodium hydroxide. If a nitrate is used some anions may remain in the carbon and upon subsequent use the nitrate may be dissolved out and get into the water. It is not desirable to have nitrates in the effluent for the same reasons that we wish to remove phosphates because they contaminate the water and cause the growth of algae. Therefore, chloride salts are more practical. It is also important that the carbon to be treated is initially dry for optimum absorption. Activated carbon can be impregnated by simply dropping it into a solution containing the metallic chloride and by decanting the solution leaving the carbon wet and saturated. In practice, maximum saturation is obtained by exposing the carbon to a dilute solution, mixing it and adding increased concentrations of the metallic chloride until the carbon is free flowing and has been saturated with the solution. The carbon has been saturated so that it is still free flowing and dry to all appearances is then dried at 105-l25C between one and two hours. The carbon is then removed from. the oven and allowed to air cool. The carbon is then treated with a solution, 540% concentration, of sodium hydroxide. It is advantageous to determine in advance the amount of aluminum, zinc, magnanese, magnesium, calcium or iron that has been added by the previous treatment so that the treatment with the sodium hydroxide will be stoichiometric. Optimum results .are obtained when an excess of sodium hydroxide is used to make the final product slightly alkaline. Sodium hydroxide reacts with any one of the above mentioned metallic solutions and converts those elements to either oxide salt, oxide or hydroxide. Finally, the treated carbon is washed in distilled water or tap water and dried at lO5-l25C between one and two hours. The activated carbon is now ready for use.  
  Of the various chlorides, iron chloride would take priority as a practical choice. Iron salts are reasonable in cost and have the additional benefit that if any iron does get into the water it will not be detrimental to the health. It is also noted that instead of sodium hydroxide, potassium hydroxide or any alkali hydroxide could be used. Sodium hydroxide is preferred due to cost. The activated carbon will remove the phosphate because the phosphate in the effluent will combine with the cations that have been introduced into the carbon, i.e., the aluminum, manganese, magnesium, zinc, calcium, iron cations. The cations will combine with the phosphates to form an insoluble compound that will be retained by the carbon.  
  The previous chemical process requires two major steps. There is another way of impregnating the carbon for removal of phosphates which requires only one step. This particular chemical. process is accomplished by using lithium hydroxide directly on the carbon. The carbon is continuously stirred in a dilute solution of lithium hydroxide while small increments of lithium hydroxide are added. After saturation with the lithium hydroxide the carbon is free flowing and dry in appearance. The carbon is then dried at 105C for about an hour and air cooled. When the phosphate comes in contact with the lithium cations it is converted to lithium phosphate which is insoluble and will be retained by the carbon. It would also be possible to use an alkali earth metal hyroxide, specifically, calcium or barium hydroxide for direct impregnation. Sodium and potas sium hydroxide are not useable due to the extreme solubility of their phosphates.  
  It is understood that the invention is not limited to the exact details described for obvious modifications will occur to persons skilled in the art. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as described.  
 a carbon structure;  
 a deposit within said carbon structure of a metallic cation producing compound selected from the group consisting of oxy-salts or oxides or hydroxides of aluminum, manganese, magnesium, zinc, iron, calcium and lithium whereby the soluble phosphates will combine with the cations deposited on the carbon to form a water insoluble phosphate retained on the carbon, when the activated carbon