Treating real textile wastewater with a hybrid adsorption‐membrane system: Optimization and energy consumption

Abstract This study advances the development of hybrid membrane processes, specifically adsorption–ultrafiltration–nanofiltration (A–UF–NF) sequences, for textile wastewater treatment. The novelty lies in applying Response Surface Methodology to optimize the hybrid configuration, revealing synergistic interactions that overcome limitations of standalone nanofiltration (low flux) and ultrafiltration (insufficient decolorization). A comprehensive evaluation links optimized operating parameters with performance indicators such as flux, fouling, energy use, and cost, using Hermia's fouling model. The findings provide a holistic framework for designing efficient, sustainable membrane‐based systems, moving beyond fragmented approaches toward integrated process engineering. Industrial relevance is demonstrated through the optimized adsorption–NF process, which proves practical and scalable. It achieves >97% decolorization, high organic contaminant removal, improved permeate flux, and low specific energy consumption (0.317 kWh·m −3 ). The operating cost of 0.116 USD·m −3 highlights its economic viability for full‐scale deployment. Furthermore, successful membrane regeneration addresses fouling and durability challenges, ensuring long‐term sustainable operation. Overall, this research establishes a robust, data‐driven framework enabling textile industries to adopt advanced, cost‐effective membrane technologies. It supports water reuse, regulatory compliance, and environmental sustainability, offering a significant step toward industrial‐scale implementation of integrated hybrid processes.