Polyaniline‐Coated Magnesium Ferrite Nanocomposite: Synthesis, Characterization, Fabrication Cost Analysis and Dye Sorption Behavior with Scale‐Up Design

Abstract

Abstract In this research, polyaniline‐based magnesium ferrite nanocomposite (Pan−MgF−NC) was synthesized for the sequestration of cationic brilliant green (BG) dye. The Pan−MgF−NC revealed surface area of 56.19 m 2 /g and pore volume of 0.056 cc/g, with 20 to 40 nm of pore diameter. The impact of numerous parameters namely, solution pH, sorbent dose, dye initial concentration, and sonication time were explored and maximum dye abatement (90.28 %) was detected at solution pH of 8.0. The dominant mechanisms for the sequestration of BG onto Pan−MgF−NC were π‐π interactions, H‐bonding, and electrostatic attraction. The sorption kinetics of experimental data well fitted to pseudo second order analysis and Langmuir isotherm was the most consistent isotherm model with maximum uptake capability of 294.12 mg/g. Response surface methodology (RSM) was exhibited that the experimental BG removal (88.70 %) and model assimilated BG removal (89.13 %) are close to each other. Investigation related to scale‐up design also studied for large volume of industrial effluent. The laboratory scale fabrication cost of Pan−MgF−NC was found to be ∼85.00 USD/kg. The BG elimination efficacy with Pan−MgF−NC decreases from 90.13 % to 81.93 % after the fifth cycle, demonstrating the strong stability and reusability of Pan−MgF−NC.