Optimizing catalytic performance: Reduction of organic dyes using synthesized Fe3O4@AC magnetic nano-catalyst

Abstract

This article presents a sustainable method for the catalytic reduction of both simple and binary dye systems using magnetic activated carbon (Fe3O4@AC) synthesized from almond shells, an agricultural waste biomass. The reduction of methylene blue (MB) and Congo red (CR) was investigated in the presence of NaBH4, and a series of physical-chemical experiments were conducted to elucidate the mechanism of dye conversion and its performance. The results confirmed the successful synthesis of Fe3O4 nanoparticles on the activated carbon surface. The calculated rate constants in a simple system were 0.34 min⁻1 for MB and 0.25 min⁻1 for CR, in the binary system, the Fe3O4@AC catalyst demonstrated enhanced selectivity for the cationic MB dye, attributable to the robust, attractive surface charge. The study aimed to enhance catalytic performance by employing optimization curves generated from a three-level Box-Behnken Design (BBD) simulation. Experimental results indicated that the optimal catalyst dose, dye concentration, and reaction duration were 4–7 mg, 80–120 mg/L, and 5–20 min, respectively. Response surface methodology (RSM) was developed by processing the findings from 17 replicated experiments using a two-quadratic polynomial model, establishing a functional link between the experimental parameters and MB conversion. Optimal conditions for MB conversion were determined to be 7 mg of catalyst, 80 mg/L of MB concentration, and a reaction time of 12.5 minutes, resulting in an estimated conversion rate of 99.99 %. This prediction was validated by experimental findings, with regression analysis confirming a high correlation (R2 > 0.99) between the predicted and observed values. Additionally, the Fe3O4@AC catalyst demonstrated good recyclability and stable performance over three consecutive cycles, maintaining high conversion efficiency without loss of performance. These findings demonstrate that Fe3O4@AC is a viable approach for the rapid and efficient remediation of dyes in water.