Enhanced cadmium (Cd2+) removal from wastewater using integrated inclined plate settler and composite adsorbent coating

Bottlenecks inherent in batch and column adsorption configurations have impeded the implementation of the adsorption technique in large-scale wastewater treatment systems. This study mainly aimed to develop an innovative wastewater treatment prototype that integrates inclined plate settlers (IPS) and composite adsorbent coating (CAC). The objective is to enable the removal of Cd²⁺ from aqueous solutions in a continuous setup, thereby enhancing its practicality for large-scale applications. The combined IPS-CAC system was optimized at various angle of inclination (θ), influent flow rate (Q) and adsorbate initial concentration (C_o) using the Box–Behnken Design (BBD) of the Response Surface Methodology (RSM). At optimized operating parameters (θ = 45°, Q = 5 ml/min and C_i = 1.87 mg/L) the IPS-CAC Cd²⁺ predicted (R² = 0.9926) and experimental removal efficiencies were 75.8% and 69.7 ± 4.67%, respectively. The IPS-CAC breakthrough adsorption capacity was 9.6 mg/g. Comparing IPS-CAC performance with a tank without plates and IPS with plain plates, the Cd²⁺ removal efficiencies were 2.4 ± 0.1% and 4.6 ± 1.1%, respectively, confirming the synergistic effect of IPS and CAC. Additionally, breakthrough curves were acquired for various flow rates, cadmium influent concentrations, and plate inclination angles. Only a 10% decline in the removal effectiveness (from 69.7 to 59.7%) of the CAC after three adsorption–regeneration cycles was observed, indicating its stability for heavy metal removal. The results underpin the potential of using IPS-CAC for industrial wastewater treatment and enhancing the use of adsorption on a larger scale.