Performance evaluation, scale‐up design, and economic analysis for remediation of iron‐containing wastewater using cow manure biocarbon

Abstract Excessive iron in wastewater poses a significant threat to aquatic ecosystems due to its toxic effects on aquatic life and its contribution to oxygen depletion. When applied to cropland, iron‐containing wastewater leads to soil acidification and reduces phosphorus availability, thereby impacting agricultural productivity. Addressing this issue requires techno‐economically viable remediation strategies. This study investigates cow manure biocarbon as a sustainable adsorbent for iron sequestration from wastewater. Batch experiments using synthetic solutions with 10–50 mg L −1 iron examined the influence of adsorbent dose, pH, and contact duration on iron removal efficiency. The cow manure biocarbon was characterized for evaluation of its physicochemical attributes. Adsorption achieved nearly 84% removal efficiency under optimal conditions of 120 min contact time, pH 9, and 0.25 g adsorbent dosage at 30°C. Adsorption isotherm data were modelled using the Langmuir and Freundlich models, with the Langmuir isotherm providing the best fit, as indicated by a low SSE (0.7056), RMSE (0.84), χ 2 (0.0044), and a high R 2 value of 0.995. Kinetic data were evaluated using pseudo first order and pseudo second order models, revealing that the process followed pseudo first order kinetics, evidenced by a low SSE (0.0144), RMSE (0.12), χ 2 (0.0044), and a high R 2 value of 0.9888. The adsorbent demonstrated good reusability and stability over five regeneration cycles. To assess the real‐world application of this process, a theoretical scale‐up design for wastewater remediation was developed. Furthermore, an economic and preliminary life cycle assessment was conducted to evaluate cost‐effectiveness and sustainability aspects.