Abstract: A reactor apparatus for continuous manufacturing of porous carbon material by halogenation of carbides is provided. The reactor apparatus comprises a sample loading assembly, a reactor positioned within a metal housing and in closed circuit communication with the sample loading assembly, and a material receiving assembly. The sample loading assembly loads samples of carbides into the reactor. The metal housing maintains an inert atmosphere around the reactor. The reactor defines one or more process paths for transporting samples of carbides through a halogen atmosphere and/or a post-treatment atmosphere for yielding porous carbon material. Process vents, positioned on the reactor and the metal housing, pass inert gases and reactant gases past the samples of carbides at predetermined temperatures and exit process gases through a condenser unit. The condenser unit traps metal halide by-products.

Abstract: Purity (chemical composition) and porosity of carbons are important for most of their applications. There are several methods of making porous carbons. Carbide derived carbon represents a method of manufacturing carbon from metal carbides by thermochemical etching of metals and/or metalloids at elevated temperatures. This invention provides a method of manufacturing carbide derived carbon with higher purity. The produced carbons can be used in several applications where higher purity carbons are desired including but not limited to gas chromatography, liquid chromatography, supercapacitors, batteries, fuel cells, hemodiafiltration, enterosorbent, and toxin removal from biological fluids.