Dye Removal From Tannery Wastewater Utilizing Footwear Waste: A Sustainable Approach

ABSTRACT Waste‐to‐3R (reduce, reuse, and recycle) is a promising mass balance approach in the leather sector for addressing the current challenge of overproduction of rubber sole waste in the footwear industry and dye pollution in tanneries. In this study, low‐cost charcoal derived from discarded natural rubber (NR) soles was effectively employed to remove anionic and cationic dyes from a model tannery dye solution, aligning with mass balance approaches in the leather sector. Discarded rubber charcoal (DRC) was prepared at 350°C using a self‐fabricated pyrolytic cell. The resulting charcoal was then dried, ground, and separated through 40‐mesh size lab‐scale sieves, and it was subsequently employed for the removal of dyes from tannery wastewater. The dye removal performance was optimized by adjusting parameters such as dosage, pH, contact time, and concentration. The maximum adsorption capacity and removal efficiency of the anionic acid dye (AD) were found to be 158.22 mg/g and 88.39% at pH 1, respectively, while those of the cationic methylene blue dye were 166.18 mg/g and 85.53% at pH 12, respectively, between 15 and 30 min, depending on the DRC conditions. Fresh charcoal and dye‐loaded charcoal were characterized through Fourier transform infrared spectroscopy, x‐ray diffraction, Brunauer–Emmett–Teller, scanning electron microscope (SEM), and transmission electron microscope with Energy‐Dispersive X‐ray (EDX) Spectroscopy for respective functional groups and morphology studies, and zeta potential measurements were employed to characterize the charcoal surface charge. The SEM image revealed that the shape of the DRC particles resembles a honeycomb structure, with an average size of 573.56 µm. The adsorption kinetic study indicates that the Freundlich isotherm model and pseudo‐second‐order kinetics were well‐fitted for dye removal in this study. The charcoal exhibited robust stability, retaining its capacity of 57.42 mg/g of AD and 44.94 mg/g of MB dye after four reuse cycles. This resilience was observed in treatment with various desorption agents, including HCl, CH 3 COOH, NaOH, and C 2 H 5 OH. The findings of this study suggest that NR‐derived charcoal could be used as a successful substitute for commercial activated carbon in wastewater treatment to get rid of the acid and basic dyes of the leather industry. Based on the observed results, a plausible mechanism was also proposed.