| Summary: | The Taguchi method was employed to determine the optimal conditions for producing activated carbon using palm kernel shells for methylene blue removal from aqueous solution. The effects of impregnation ratio, carbonization temperature, and time on the carbon burn-off percentage were investigated. Statistical analysis indicated that the optimal conditions for activated carbon were an impregnation ratio of 1.5, carbonization temperature of 600 °C, and carbonization time of 90 min, with temperature having the most significant impact on the response. A mathematical model for carbon burn-off was created through regression analysis of the independent variables. The proximity between the predicted values and the experimental data justifies the significance of the model. A confirmation run with a 95% confidence level validated the optimized results and fell within the prescribed limit. Activated carbon prepared under optimal conditions, with a BET surface area of 420.66 m2/g and a total pore volume of 0.18 cm3/g, recorded the highest carbon burn-off (63.38%) compared to other set of conditions. The adsorption equilibrium and kinetic data were well described by the Langmuir isotherm and pseudo-second-order kinetic model, respectively. A maximum methylene blue adsorption capacity of 56.49 mg/g after 180 min was observed, indicating its potential as an effective adsorbent for the removal of synthetic dyes in wastewater. © The Author(s), under exclusive licence to Springer-Verlag GmbH Germany, part of Springer Nature 2025.
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