Iron-doped catalyst synthesis in heterogeneous Fenton like process for dye degradation and removal: optimization using response surface methodology

Iron-doped hydrochar can effectively remove the methyl orange dye (MO). In this study, iron-doped hydrochar (5% Fe@BC) was successfully synthesized through a two-step hydrothermal carbonization (HTC) process, using FeSO₄.7H₂O and sawdust. It was subsequently employed for MO removal. The characterization of the synthesized Fenton-like catalyst (5% Fe@BC) was conducted, using scanning electron microscopy, Fourier-transform infrared and X-ray diffraction techniques to confirm the presence of iron species. The effects of different operating parameters such as catalyst mass, H₂O₂ concentration, solution pH, organic pollutant concentration, and reaction temperature have been examined. The Box-Behnken design combined with three factors: catalyst mass X₁, temperature X₂, organic pollutant concentration X₃. The response surface methodology coupled with Box-Behnken Design was used to optimize the key variables and response. With this approach, an exhaustive assessment of the variables influencing the optimization process was performed. A significant quadratic model was generated through analysis of variance with a P-value of 0.0001 and an R² of 0.99. This confirms a strong relationship between the variables and the response, as well as a high level of model predictability. The optimum conditions were achieved with a catalyst mass of 0.5 g/L, a temperature of 35.5 °C, and an MO concentration of 50 mg/L. The result indicates that 93% of the discoloration efficiency was achieved within 60 min under the optimal conditions. Iron doping in the (5% Fe@BC) plays a crucial role in the degradation and removal of MO. Therefore, the 5% Fe@BC prepared from sawdust and iron salts (FeSO₄·7H₂O) through a two-step HTC process is an inexpensive and effective catalyst for removing organic pollutant from aqueous solutions, using heterogeneous Fenton-like process.