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This study introduces a method to create porous carbon structures with intricate internal voids. 3D-printed PLA acts as an internal sacrificial template, combined with carbonized whey powder as the porous carbon matrix. Sintering whey powder at 150°C yields solid pieces that, upon carbonization, result in highly porous carbon objects while maintaining the original mold shape. Temperature control ensures successful whey powder sintering before PLA melting. The use of PLA sacrificial templates, along with whey carbonization, allows for developing devices with finely tailored internal voids, as demonstrated through a double Archimedean spiral reactor with porous carbon walls. [ABSTRACT FROM AUTHOR]

Novel customised carbon monoliths with a high specific surface area were synthesised by carbonisation plus activation of dehydrated whey powders, a biomass byproduct of the dairy industry. The whey powders were casted directly by pouring them into a desired mould. After a pseudo-sintering process promoted by the self-reaction of the whey components (mostly lactose and whey proteins) at moderate temperatures (ca. 250 °C), 3D porous carbons were obtained. The process did not require any binder or external overpressure to prepare the 3D porous carbons. Upon thermal activation with CO2 or chemical activation with H3PO4 and KOH, the shape of the monolithic structure was preserved after the development of a microporous network (SBET up to 2400 m2/g). Both thermal and chemical activation had little effect on the macroporosity of the monoliths. Activation of these 3D carbons had to be performed with care to avoid heterogeneous skin/core activation and/or overactivation. Highly porous monoliths (SBET of 980 m2/g; open porosity of 70%) with outstanding compressive strength (10 MPa) could be obtained by thermal activation (CO2) of whey monoliths at 850 °C for 1.5 h. Additionally, the use of whey as a precursor provided the carbon monolith with a relatively high nitrogen content (ca. 3 wt.%). [ABSTRACT FROM AUTHOR]

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