• Smaller activated carbon particles significantly enhance methylene blue adsorption capacity due to increased surface area and pore accessibility.
• Adsorption kinetics follow a pseudo-second-order model, indicating chemisorption as the rate-limiting step.
• Langmuir isotherm best fits equilibrium data, suggesting monolayer adsorption on a homogeneous surface.
• Thermodynamic analysis reveals spontaneous and exothermic adsorption, favoring lower temperatures for efficient dye removal.
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