Electrolytic synthesis of γ-Al2O3 nanoparticle from aluminum scrap for enhanced methylene blue adsorption: experimental and RSM modeling

The presence of methylene blue (MB) dye in wastewater has raised concern about human health and environmental ecology due to potential carcinogenic, and mutagenic effects. Therefore, this work aims to remove MB dye from wastewater using γ-Al2O3 nanoparticles synthesized from aluminum scrap via simple electrolytic method. The successful synthesis of the adsorbent was confirmed by a range of spectroscopy and microscopy techniques, including XRD, SEM, FTIR, and BET. The central composite design (CCD) of the response surface methodology (RSM) method was used to optimize the processing parameters such as solution pH, contact time, initial MB concentration, and adsorbent dose. The ANOVA results clearly shows that the quadratic model (p < 0.0001) was sufficient to the best predicting of the removal performance of MB dye (R2 = 0.9862). The optimum condition for the maximum MB dye removal (98.91%) was achieved at solution pH of 8.298, initial MB concentration of 31.657 mg/L, adsorbent dose of 0.387 g/L, and contact time of 46.728 min. Nano-γ-Al2O3 was shown to have a good surface area of 59 mg2/g by BET analysis. The adsorption kinetics follows the pseudo-second-order model (R2 = 0.997). With a maximum adsorption capacity of 137.17 mg/g, the Langmuir isotherm model (R2 = 984) provides the best fit to the adsorption isotherm data, indicating a monolayer adsorption process. Furthermore, thermodynamic analysis demonstrated that the adsorption of MB dye was an endothermic and spontaneous process. The reusability study showed that γ-Al2O3 nano-adsorbent retained 85.08% of its original removal efficiency after five cycles. According to the findings of the study, MB dye molecules were taken up by γ-Al2O3 nano-adsorbent via hydrogen bond formation, Van der Waals interaction, and electrostatic attraction. Therefore, γ-Al2O3 nanoparticles can be used as a potentially eco-friendly and low-cost adsorbent for the removal of MB dye from aqueous solutions.