Heterogeneous photocatalysis via combination of catalyst and UV irradiation is one of the most promising advanced oxidation processes for degradation of water-soluble organic contaminants. Herein, different photocatalysts (ZnO/CFA, TiO2/CFA, and TiO2-ZnO/CFA) were synthesized via sol-gel and impregnation techniques and applied for the degradation of acid blue 25 (AB25) dye in aqueous solution under UV light in a photoreactor. Various spectroscopic techniques (XRF, XRD, BET, FTIR, UV–vis DRS, TEM and EDS) were employed to evaluate the chemical structure, functional groups, textural, and optical properties of the binary and ternary composites. TiO2-ZnO/CFA displayed rapid degradation of AB25 as compared to ZnO/CFA and TiO2/CFA, owing to the dualistic photocatalytic sites. The prepared TiO2-ZnO/CFA composite was used in synergy with the photoreactor for photocatalytic degradation process optimization, and the optimum degradation conditions in relation to initial AB25 concentration (10 mg/L), UV light intensity (18 W/m2), flow rate (12.5 L/h), and irradiation time (150 min) as input parameters were determined using Taguchi design approach. The maximum photocatalytic degradation efficiency was 98.79±0.94% under those aforementioned conditions, indicating that the synergies between the photoreactor and the TiO2-ZnO/CFA photocatalyst resulted in the effective destruction of AB25 dye molecules. Furthermore, the spent photocatalyst was easily removed from the degraded solution and reused up to nine times. After 150 mins of UV irradiation with TiO2-ZnO/CFA photocatalyst, almost complete mineralization of AB25 solution was achieved.
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