The development of low-energy and sustainable materials for carbon capture is critical to climate change mitigation. In this study, activated carbon was synthesized from tea twigs waste (Camellia sinensis) via pyrolysis at 300 °C followed by KOH chemical activation at an ultra-low temperature of 200 °C. The optimized sample (AC-A2B4) exhibited a high BET surface area of 542 m2g−1, narrow average pore diameter (1.936 nm), and a CO2adsorption capacity of 2.867 mmol g−1at 25 °C—surpassing many adsorbents produced under conventional high-temperature conditions. Characterization using BET, FTIR, XRD, and SEM-EDX confirmed the presence of abundant polar surface functionalities (e.g. –OH, C = O), high carbon content (83.5%), and an amorphous mesoporous structure conducive to CO2physisorption and chemisorption. Although the initial N2uptake at low P/P0(< 0.1) suggests the presence of narrow pores, the overall isotherms exhibited Type IV characteristics, indicative of dominant mesoporosity. Isotherm modeling showed strong agreement with the Langmuir model (R2 = 0.994), indicating monolayer adsorption on a surface with uniform high-affinity sites. Regeneration experiments over five cycles demonstrated minimal capacity loss (<5%), while life cycle analysis revealed ∼70% lower energy consumption compared to traditional activation routes. This study introduces a novel, energy-efficient pathway to produce mesoporous, high-performance CO2adsorbents from agro-industrial waste under mild processing conditions, offering scalable potential for decentralized carbon capture and sustainable manufacturing. © The Author(s) 2025. This article is distributed under the terms of the Creative Commons Attribution-NonCommercial 4.0 License (https://creativecommons.org/licenses/by-nc/4.0/) which permits non-commercial use, reproduction and distribution of the work without further permission provided the original work is attributed as specified on the SAGE and Open Access page (https://us.sagepub.com/en-us/nam/open-access-at-sage).