The Indian textile industry plays a vital role in the supply chain and marketing of garments and diverse handloom products, thereby strengthening India's commercial position in the global market. The exceptional performance of textiles in the regions of Gujarat, Tamil Nadu, Maharashtra, Rajasthan, Madhya Pradesh, and Punjab in terms of woollen production facilities. According to the Annual Survey of Industries (ASI), 23.6% of the textile sector in Gujarat exhibits high levels of production.

Textile industries generate a large volume of complex effluents during the processing of clothes, and before discharging, which is a high organic and inorganic effluent load on the environment. Azo, Benzo, Cationic, Xanthene, a group of dyes that are effective in our humanity and the abiotic life cycle. According to the Central Pollution Control Board (CPCB) survey, 92 million tons of effluent were generated in FY23-24. This wastewater often shows high TDS, salinity, alkalinity, and electrical conductivity, primarily originating from salt-intensive dyeing processes. Additionally, textile wastewater contains heavy metals (Cr, Cu, Ni, Zn), formaldehyde-based resins, and chlorinated compounds, posing ecotoxicological and human health risks. Some of the most carcinogenic groups of dyes are the reactive dyes, which are harmful and highly soluble in water molecules, for example, RB21 (Reactive Turquoise Blue 21) dye. The general molecule's formula is C₄₀H₂₅CuN₉O₁₄S₅, represents a copper phthalocyanine reactive dye with multiple functional groups (nitrogen heterocycles, sulfonic groups) around a central Cu atom. Typically contains reactive vinyl sulfonyl (–SO₂–CH=CH₂) or sulfatoethylsulphonyl groups that can form covalent bonds with hydroxyl (–OH) groups of cellulose fibres during the dying process. One of the most advanced research studies was successfully published in a reputed journal, which one is the advance solutions to degrade this carcinogenic pollutant by using the AOPs (Advance Oxidation Processes) technique.
Catalyst is the altering the rate of the reaction. One of the most susceptible, highly active, emerging, and advanced materials in the presence of visible light also enhances COD, BOD, and DO rates to make water drinkable. Recent breakthroughs to mineralise faster RB21 with the combination of materials with hybrid techniques like Photocatalyst+Ultrasonication, UV+Ozonation, Corona Discharge Plasma with Fe2+ addition,n etc.
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Method
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Approx. RB21 Removal
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Notes
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Corona plasma + Fe²⁺
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~100% color removed, ~83 % COD ↓
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Advanced oxidation
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Photo‑ozonation
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~99 %
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Very short reaction times
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SmFeO₃‑rGO + ultrasound
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High degradation (faster)
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Effective on the actual effluent
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Fly ash adsorption
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Moderate capacity
(~105 mg g⁻¹)
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Very low cost
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Photocatalysis with MgFe2O4
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93 % removal rate
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AOP, low cost
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Figure 1: Advance Oxidation Process (AOPs) Techniques performance over RB21 dye degradation (Predictive analysis) (a) Various AOPs Utilised for RB21 dye (b) Concentration variation over RB21 with Vis. + H2O2
Figure 1 assumes a RB21 dye concentration of 25 ppm, utilising AOPs techniques, including ozonation, photocatalysis, photo-Fenton, and UV and Vis light irradiation with H₂O₂ as an oxidant to break the interaction between the dye and H₂O molecules.
Azo bond is extremely ozone-sensitive -N=N- bond undergoes rapid cleavage, R-N=N-R + Ozone to form aromatic amines with smaller fragments. When using ozonation, one ozone molecule can break chromophoric structure, leading to rapid decolourisation, but at high concentrations of RB21,
Ozone + OH− → •OH + O2
•OH+RB21→fragmented intermediates
Why its happening, ozonation destroys chromophores first, and some aromatic fragments remain due to not destroyed completely, like sulfonated benzene/naphthalene derivatives. It becomes colourless but lack of degradation onto benzene rings. Why aromatic fragments are hard to remove becausethey have resonance stability and can react with ozone slowly in the presence of hydroxyl radicals.
Figure (a) compares the degradation performance of Reactive Blue 21 (RB21) dye utilizing various advanced oxidation processes (AOPs) across reaction time. All processes demonstrate a time-dependent rise in degradation efficiency, indicating continual reactive oxygen species formation. Initial degradation is modest due to negligible radical formation. UV/H₂O₂ and visible light/H₂O₂ systems outperform ozonation, photocatalysis, and photo-Fenton reactions in degradation efficiency as irradiation time increases. Superior performance of peroxide-assisted systems is due to increased photolysis of H₂O₂, resulting in numerous hydroxyl radicals (•OH) with strong non-selective oxidation capability. The photo-Fenton process degrades effectively by Fe²⁺/Fe³⁺ redox cycling under light, while photocatalysis and ozonation have reduced efficiency due to electron-hole recombination and restricted oxidant use. The study shows that light-assisted H₂O₂-based AOPs effectively degrade RB21.
Figure (b) shows how initial RB21 concentration impacts degradation efficiency during visible light/H₂O₂ treatment at various irradiation periods. Increased dye concentration decreases degradation efficiency, suggesting faster degradation kinetics at lower initial concentrations. Low dye concentrations (10–25 ppm) increase efficiency due to better light penetration and more hydroxyl radicals per dye molecule. In contrast, greater concentrations (75–100 ppm) impair efficiency due to the inner filter effect, increased solution opacity, and extra dye molecules and intermediate degradation products competing for hydroxyl radicals. However, continuous irradiation boosts deterioration at all concentrations, proving the durability of the visible light/H₂O₂ combination. These findings show that initial dye concentration controls reaction kinetics and AOP efficiency.
In the figure, sets for the degradation of the pollutants with various techniques for the effluent treatment. The first graph shows the results based on the different concentration 10, 20, and 30 ppm over the US (Ultrasound) in the presence of UV light, with PDS and a certain amount of catalyst dosage were estimated. That graph shows that the highest degradation range is at 10 ppm, while 30 ppm shows the results are much lower due to the increase in the concentration of effluent.
Figure
1:
Overall Lab Experimental setup for Hydrogen Production after wastewater
treatment
Wastewater
treatment has emerged not only as a critical environmental necessity but also
as a promising platform for sustainable hydrogen production. Our studies and
reviews for advanced wastewater treatment methods – namely, electrochemical,
photocatalytic, biological, and thermochemical processes but the sol-gel
approach enhanced the morphology of the spinel structure. Among these,
electrochemical methods such as electrocoagulation and microbial electrolysis
cells have shown hydrogen yields up to 1.2 m3 of wastewater under
optimised conditions, while photocatalytic degradation using solar-assisted
systems reports quantum efficiencies reaching 8-12% with Hydrogen rates around
250 µmol/h·g_cat. Thermochemical gasification of sludge can yield 4-5 wt% of
Hydrogen from dry biomass.
The
incorporation of spinel-type catalysts enhances these processes. Spinels such
as AlFe2O4, with other transition metals, Co, Mn, Zn, and Ni, have demonstrated
excellent redox stability, high oxygen evolution reaction activity, and
resistance to deactivation under wastewater treatment conditions. For instance,
Aluminium used in photoelectrochemical water splitting under restimulated
sunlight achieved a current density of 12 mA/cm2 at 1.23 V vs RHE,
with a Faradic efficiency of over 85%, but another spinel not receive a higher
yield of hydrogen. This review highlights the synergistic role of spinel oxides
in wastewater valorisation and hydrogen production, emphasising the importance
of material engineering and process optimisation to drive sustainable energy
and environmental goals. Aluminium ferrite (AlFe₂O₄), a spinel-structured mixed
metal oxide, has garnered significant attention for its multifunctional role in
both wastewater treatment and hydrogen production. Its inherent physicochemical
properties—namely, high thermal and chemical stability, redox-active metal centres,
and magnetic separability—render it an efficient and reusable catalyst. In
wastewater treatment applications, AlFe₂O₄ exhibits remarkable activity in
heterogeneous Fenton-like oxidation processes, facilitating the degradation of
recalcitrant organic pollutants via hydroxyl radical generation. The presence
of Fe³⁺/Fe²⁺ redox cycling, synergistically enhanced by Al³⁺ substitution,
improves electron transfer kinetics and structural robustness under operational
conditions. Furthermore, AlFe₂O₄ serves as a promising catalyst in hydrogen
evolution reactions (HER) and thermochemical water-splitting cycles, where its
band structure and surface characteristics promote charge carrier separation
and catalytic efficiency. The dual applicability of AlFe₂O₄ in environmental
remediation and sustainable energy systems underscores its potential as a
cost-effective and scalable material platform for integrated catalytic
technologies. Proton exchange membrane fuel cells (PEMFCs) represent a leading
technology for clean and efficient energy conversion, relying on the continuous
supply of high-purity hydrogen gas as the primary fuel. In PEMFC systems,
hydrogen undergoes electrochemical oxidation at the anode, producing protons
and electrons that are utilised to generate electric power, while oxygen
reduction occurs at the cathode to form water as the sole by-product. The
sustained operation of PEMFCs necessitates a reliable hydrogen source, either
from compressed hydrogen cylinders, metal hydrides, or in situ hydrogen
generation systems such as reforming or hydrolysis. The choice of
electrocatalyst is crucial to achieving high performance and durability;
platinum (Pt) remains the benchmark anode and cathode catalyst due to its
excellent catalytic activity and stability. However, efforts to reduce Pt
loading have led to the development of Pt-alloys (e.g., Pt-Co, Pt-Ni) and
non-precious metal catalysts (e.g., Fe-N-C materials) with enhanced catalytic
efficiency and cost-effectiveness. The hydrogen supply rate must be precisely
controlled to meet the stoichiometric and pressure requirements of the fuel
cell stack, typically maintaining a hydrogen flow rate of 0.5–1.0 NL/min per 1
kW of power output. Efficient humidification, thermal management, and membrane
hydration are also critical to sustain proton conductivity and overall system
performance. This abstract highlights the integrated considerations of hydrogen
delivery, catalyst optimisation, and fuel cell operating conditions essential
for the continuous and efficient operation of PEM-based hydrogen fuel cells.
Aluminium
dross, a high-temperature by-product generated during the aluminium smelting
and recycling process, represents a significant secondary resource rich in
metallic aluminium and alumina phases. Its valorisation for hydrogen production
not only offers a sustainable waste management strategy but also contributes to
renewable energy generation. The residual metallic aluminium in the dross
readily reacts with water in alkaline or acidic media, producing hydrogen gas
through a corrosion-driven hydrolysis reaction. Among the various approaches,
alkaline-mediated hydrolysis, particularly using NaOH or KOH solutions, is
considered the most efficient due to its ability to suppress the passive oxide
layer on aluminium particles, thereby enhancing reaction kinetics. The primary
reaction,
2Al+2NaOH+6H2O→2NaAl(OH)4+
3H2
proceeds
exothermically and can be optimised by adjusting parameters such as
temperature, pH, particle size, and stirring speed. The use of mechanical
activation (e.g., ball milling) and additives such as gallium or bismuth has
been reported to further increase hydrogen yield by disrupting the protective
alumina layer. Post-reaction residues primarily consist of alumina and sodium
aluminate, which can be further utilised in industrial applications. This
method not only enables the efficient extraction of hydrogen from aluminium
dross but also aligns with circular economy principles by converting
metallurgical waste into valuable energy resources.
Traditional
storage solutions such as high-pressure cylinders (>350 bar) or cryogenic
tanks (<20 K) are limited by high energy requirements, infrastructure costs,
and inherent safety risks. In contrast, metal–organic frameworks (MOFs) have
emerged as a class of advanced porous materials with tenable pore architectures
and ultrahigh specific surface areas, making them highly suitable for
reversible hydrogen physisorption. MOFs such as MOF-5, HKUST-1, and MIL-101
exhibit promising gravimetric and volumetric storage capacities under moderate
pressure (10–100 bar) and cryogenic conditions (~77 K), with some achieving
near or above 7 wt% H₂ uptake. Their modular chemistry allows for structural optimisation
toward enhanced binding enthalpies and sorption kinetics.
Integrating
MOF-based hydrogen storage systems with aluminium dross-derived hydrogen
generation platforms can enable on-demand hydrogen capture and controlled
release, addressing key bottlenecks in storage and transport, and paving the
way for scalable hydrogen energy systems.
Furthermore,
coupling the stored hydrogen with PEM fuel cells enables clean energy
conversion with high efficiency and zero emissions. Continued development in
catalyst engineering—particularly low-Pt or non-precious metal catalysts—can
enhance the cost-effectiveness and durability of PEMFCs. Research must also
address the dynamic integration of hydrogen generation, real-time storage
regulation, and fuel cell load response for practical deployment.
In
the broader context of circular economy and energy resilience, this combined
approach has the potential to transform metallurgical waste into a clean energy
vector. Future research should focus on system-level optimisation, lifecycle
assessment, techno-economic analysis, and scalability of the integrated
platform to support industrial and off-grid energy applications.

AlFe2O4 is a visible light active spinel ferrite
semiconductor with a narrow bandgap (1.9-2.1 eV), which might occur,
allowing it to absorb light when light hits AlFe2O4.
AlFe2O4 + hv – e- + h+
The electron (e-) goes to the conduction band, and the hole pairs are
generated in the valence band. Conduction band Electrons (e-). Electrons reduce
protons in water to generate hydrogen gas.
2H+ + 2e- = H2
H+ +organic contaminants = oxidation products (e.g., CO2,
H2O). Holes oxidise organic matter in wastewater, aiding
degradation.