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The feasibility of biomass-based activated carbons has received a huge attention due to their excellent characteristics such as inexpensiveness, good adsorption behaviour and potential to reduce a strong dependency towards non-renewable precursors. Therefore, in this research work, eco-friendly activated carbon from palm kernel shell that has been produced from one-stage physical activation by using the Box-Behnken design of Response Surface Methodology is highlighted. The effect of three input parameters—temperature, dwell time and gas flow rate—towards product yield and carbon dioxide (CO2) uptake at room temperature and atmospheric pressure are studied. Model accuracy has been evaluated through the ANOVA analysis and lack-of-fit test. Accordingly, the optimum condition in synthesising the activated carbon with adequate CO2 adsorption capacity of 2.13 mmol/g and product yield of 25.15 wt% is found at a temperature of 850 °C, holding time of 60 min and CO2 flow rate of 450 cm3/min. The synthesised activated carbon has been characterised by diverse analytical instruments including thermogravimetric analyser, scanning electron microscope, as well as N2 adsorption-desorption isotherm. The characterisation analysis indicates that the synthesised activated carbon has higher textural characteristics and porosity, together with better thermal stability and carbon content as compared to pristine palm kernel shell. Activated carbon production via one-step activation approach is economical since its carbon yield is within the industrial target, whereas CO2 uptake is comparable to the synthesised activated carbon from conventional dual-stage activation, commercial activated carbon and other published data from literature. [ABSTRACT FROM AUTHOR]

• K 2 CO 3 -activated carbon is obtained from mixtures of petroleum coke and palm shell. • Facile activation route through mechano-chemical K 2 CO 3 activation has been applied. • Box-Behnken design is used for optimization of yield and CO 2 adsorption capacity. • Optimized activated carbon shows a well-developed porosity and surface morphology. • Porous carbon from blend precursors has superior yield and CO 2 adsorption capacity. In this study, a binary mixture of petroleum coke and palm kernel shell had been investigated as potential starting materials for activated carbon production. Single-stage potassium carbonate (K 2 CO 3) activation under nitrogen (N 2) atmosphere was adopted in this research study. Effect of several operating parameters that included the impregnation ratio (1−3 wt./wt.), activation temperature (600−800 °C), and dwell time (1−2 hrs) were analyzed by using the Box-Behnken experimental design. Influence of these parameters towards activated carbon yield (Y 1) and carbon dioxide (CO 2) adsorption capacity at an atmospheric condition (Y 2) were investigated. The optimum conditions for the activated carbon production were attained at impregnation ratio of 1.75:1, activation temperature of 680 °C, and dwell time of 1 h, with its corresponding Y 1 and Y 2 is 56.2 wt.% and 2.3991 mmol/g, respectively. Physicochemical properties of the pristine materials and synthesized activated carbon at the optimum conditions were analyzed in terms of their decomposition behavior, surface morphology, elemental composition, and textural characteristics. The study revealed that the blend of petroleum coke and palm kernel shell can be effectively used as the activated carbon precursors, and the experimental findings demonstrated comparable CO 2 adsorption performance with commercial activated carbon as well as that in literatures. [ABSTRACT FROM AUTHOR]