ENHANCED ACTIVATED CARBON ANODE

Research into Hard Activated Carbon Anode (HACA) has ramped up in the past few years, spurred by the battery and super capacitor industries. Currently, lithium-ion batteries (LIB) rule the market, but recently, negatives of this technology has reached a tipping point. Let us wear our "Science" hats and take a look at the advantages and disadvantages of LIB technology:

ADVANTAGES:

• High energy density (150-200 kw/hr)

• Stable cycle life (~1,000 cycles of charge/discharge)

• Low self-discharge (2% to 3% at room temperature)

DISADVANTAGES:

• Expensive (only a few countries mine this non-renewable metal)

• Short Lifespan (20% degradation after 500 cycles)

• Explosion or fire hazard (due to thermal runaway)

• Environmental hazard (Lithium is a carcinogen) 

• Not temperature stable in extreme conditions 

Sodium-ion batteries (SIB) are a safer alternative. Sodium has similar physiochemical properties to Lithium, however it is not expensive because of its natural abundance. Carbon-based materials (hard carbons, carbon nanotubes, graphene) have been researched in recent times as anodes. HACA has risen above as the most cost effective, durable and safe anode for SIB. 

With Regenco's innovative research and manufacturing techniques, we plan to produce the most stable and efficient AC Anode component of the SIB with enhanced conductivity, high cycling stability, and high capacity retention.

PROPRIETARY PROCESS

CREATE BASE: Regenco utilizes digital vacuum microwave technology and innovative manufacturing techniques to create a mostly mesoporous (internal) activated carbon from the base coconut charcoal, using H3PO4 (phosphoric acid, around 25% concentration) as the activating agent (ratio of impregnation is around 1:3). The batch is then washed with distilled water (and NAOH if needed) to neutralize and remove remaining phosphoric acid.

Quality control testing internally and with our partner labs ensures that the mesopore ratio is ideal for further processing into a highly efficient anode.

PROCESS ANODE: To improve HACA performance and functionality, the following methods have been performed:

• Pore size and distribution control (as mentioned above) within the hard carbon can optimize ion transport and reduce volume expansion during cycling, leading to better cycling stability. Studies have shown that the optimal ratio of mesopore to micropore surface area (Smeso/Smicro) of 2.16 and mesopore to micropore volume (Vmeso/Vmicro) of 5.50 was associated with high specific capacitance, better rate performance, and improved cycling stability.

• Combining hard carbon with materials like silicon or red phosphorus can help mitigate volume expansion during cycling.

• Treat the surface of the hard carbon with short-chain organic molecules can create favorable solid electrolyte interfaces (SEIs), such as DFECs, and enhance ion diffusion, further improving cycling stability.

RECENT DEVELOPMENTS

1. May 2024 (Philippines)

• Small Excavator (1 ton)

• Harvesting Poles (25 ft)

• De-husker x 2

2. November 2024 (Philippines)

- Horizontal Airflow Carbonization Furnace with Smoke Condenser

We have received and assembled our ovens that will use biogas heating to carbonize coconut shells. The insulated oven is outfitted with two smoke capture stacks,- that has the ability to recirculate flue gases to supplement the heating process. Prior to carbonization, a high capacity vacuum pressure pump custom fitted will remove the oxygen in the oven.

- High Capacity Vacuum Pump

This pump will be used to evacuate the oven prior to carbonization. We will also use this pump to prepare Coconut Carbon for shipment. We have all export documents required.

3. July 2025 (USA) - Programmable 3-550A Vulcan Furnace (max 1200 degrees C or 2192 degrees F) with Venting function

This furnace will be fully functional by the end of July. This will be used to activate carbon in small batches. Regenco will be using H3PO4 for chemical activation. H3PO4 will be Gas byproducts (CO2) will be collected via thermal desorption/recovery equipment.

4. August 2025 (USA) - Quantachrome Autosorb-1-MP Surface Area and Pore Size Analyzer

This highly accurate control equipment will provide an accurate measurement of micropore/mesopore distribution, effective adsorptive surface area and general porosity. This will be used to determine the activation method that produces the ideal %micropore and %mesopore, as well as the quality of the AC.

5. September 2025

   • Equipment (Philippines):

     • Loader

     • HDPE tubs

     • Microwave Pasteurization Machine

   • Equipment (US)

     • Coir Presser

     • Grinder (HACA)

     • Vibrating sieves (HACA)

6. October 2025 (US) - Complete Chemical and Physical Lab Test equipment for HACA

We will build our lab equipment for testing of AC, including for the Methyl Blue/Iodine test, ash content, acidity and density. 

• Digital Weighing Scale (purchased)

• Chemistry set (dosing, Bunsen burner, glassware, etc.)

• Chemicals for testing (Iodine, Methylene Blue, etc.)

7. November 2025 (Philippines) - High Volume Transport and Logistics

• Fuso Truck (10 ft)

• 20-ft Container

• Loader (2-ton)

USEFUL LINKS

• https://www.youtube.com/@ThinkingandTinkering Robert Murray Smith discusses activated carbon nanotubes and other exciting research into power generating materials even as simple as wet paper.

• More to come!