Continuous Remediation of Congo Red Dye Using Polyurethane-Polyaniline Nano-Composite Foam: Experiment and Optimization Study

Abstract

This study employed an innovative approach, utilizing prepared dried polyurethane-polyaniline nano-composite, through in-situ polymerization, for continuous remediation of Congo red dye. Response Surface Methodology (RSM) based on the Box-Behnken design (BBD) model was utilized to optimize the processing parameters, including initial dye concentration, flow rate, and pH. The two-factor interaction (2FI) model emerged as the most significant, highlighting the influence of individual and interaction effects of the factors. Optimization of the dye remediation process yielded the optimal conditions of a flow rate of 10 mL/min, acidic pH of 5.00, and dye concentration of 20 mg/L, resulting in an impressive, predicted removal efficiency of 99.09% agreeing with the experimental value. Moreover, the maximum adsorption capacity was determined to be 329.68 mg/g. Characterization of the adsorbent material involved techniques such as Scanning electron microscopy (SEM), Fourier transforms infrared spectra (FTIR), X-ray spectroscopy (XRD), and Zeta potential analysis. This material offers a sustainable alternative in industries to treat Congo red dye before being disposed of into the environment.