From Batch to Pilot: Scaling Up Arsenic Removal with an Fe-Mn-Based Nanocomposite

Arsenic contamination in groundwater is a significant public health concern, with As(III) posing a greater and more challenging risk than As(V), due to its higher toxicity, mobility, and weaker adsorption affinity. Fe-Mn-based adsorbents offer a promising solution, simultaneously oxidizing As(III) to As(V), enhancing its adsorption. This study evaluates an Fe-Mn nanocomposite across typical batch (20 mg of adsorbent), fixed-bed column (28 g) and pilot-scale (2.5 kg) studies, bridging the gap between laboratory and real-world applications. Batch experiments yielded maximum adsorption capacities of 6.25 mg/g and 4.71 mg/g in synthetic and real groundwater respectively, demonstrating the impact of water matrix on adsorption. Operational constraints and competing anions lead to a lower capacity at the pilot (0.551 mg/g). Good agreement was obtained by the breakthrough curves at the pilot (breakthrough at 475 Bed Volumes) and the fixed-bed column studies (365–587 Bed Volumes) under similar empty bed contact times (EBCT). The Thomas, Adams-Bohart, and Yoon-Nelson models demonstrated that lower flow rates and extended EBCT significantly enhance arsenic removal efficiency, prolonging operational lifespan. Our findings demonstrate the necessity of continuous-flow experiments using real contaminated water sources, and the importance of optimising flow conditions, EBCT and pre-treatment, in order to successfully scale up Fe-Mn-based adsorbents for sustainable arsenic removal.