Exploring a Novel Aspergillus terreus Mycelial-Silica Oxide Composite as a Sustainable Adsorbent of Dye Wastewater: Synthesis, Optimization, and Safety Evaluation

Azo dyes demonstrate dose-dependent carcinogenic and mutagenic effects in exposed cells. Among remediation approaches, microbial adsorption is the most sustainable and environmentally friendly method for eliminating azo dyes. A novel Aspergillus terreus silica composite was developed as a sustainable adsorbent for crystal violet dye (CVD) removal. The fungal strain was isolated from dye wastewater and was genetically identified by 18S rRNA gene sequencing. Dried mycelia of A. terreus (PX920301) were combined with SiO2 (1:1 w/w) through iterative hydration-drying cycles, yielding a composite characterized by FTIR analyses. Removal CVD %, adsorption capacity, and CVD residual were calculated, and the adsorption process was optimized using Box–Behnken design (four factors, 25 runs). The biosafety of the composite was assessed for phytotoxicity and microbial toxicity. The composite was also applied to real dyes wastewater collected from the bacteriological laboratory. Aspergillus terreus-silica composite showed the highest CVD removal percentage by 85.4%, adsorption capacity (qe) 121.1 mg/L, and lowest CVD residual by 7.26 mg/L, followed by the dried active mycelia (DA-mycelia) with CVD removal 40.23%, adsorption capacity (qe) 57.05 mg/L, and CVD residual by 29.73 mg/L. Optimization data cleared that the maximum experimental values of CVD removal (%) was 99.59% (predicted value 100%) obtained in run number (4) using initial CVD concentration (200 mg/L), pH (8), adsorbent composite weight (0.1 g), and contact time (48 h). Biosafety evaluation demonstrated negligible phytotoxicity against Triticum aestivum seedlings post-treatment, with restored germination and growth comparable to controls. Microbial toxicity assays via well-diffusion to seven microbial isolates confirmed no toxic activities against the tested bacteria, yeast, and fungi, underscoring the composite’s environmental safety. The composite could decolorize the real dye wastewater of laboratories by 95.37%. In conclusion, A. terreus mycelial-silica composite offers a cost-effective, sustainable, and eco-friendly alternative solution for dye bioremediation.