Optimization of anionic dye removal using cross-linked chitosan composite as eco-friendly bio-adsorbent

The environmental impact of wastewater discharged from the textile dyeing industry has a significant challenge and influence on aquatic ecosystems and human health if not properly managed. This study aimed to develop a novel cross-linked chitosan composite, denoted as chitosan/fly ash/polyvinyl alcohol (Ch/FA/PVA), as a bio-adsorbent for removing Congo Red (CR) textile dye from industrial wastewater. The synthesis involved the incorporation of FA into the chitosan matrix at various ratios to optimize the process. A specifically tailored composite, Ch/FA0.75/PVA, exhibited superior performance with a remarkable 99.7% CR removal under optimum conditions: adsorbent dose (0.9 g/l), contact time (50 min), and dye concentration (40 mg/l). The characterization of Ch/FA0.75/PVA through SEM-EDX, BET, FTIR, and pHzpc confirmed its suitability for adsorption. Employing Box-Behnken design and analysis of variance (ANOVA) facilitated the optimization of key adsorption variables. The Freundlich model described the adsorption equilibrium, indicating a maximum adsorption capacity of 263.15 mg/g for CR dye. The pseudo-second-order model demonstrated favorable kinetics. The study was scaled up to the practical application of Ch/FA0.75/PVA in a pilot plant for industrial wastewater treatment, revealing substantial removal percentages for dye, color, COD, BOD5 and TDS. This comprehensive approach highlights the promising efficacy of Ch/FA0.75/PVA in addressing environmental concerns associated with textile dye wastewater.