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Nano zero-valent iron (nZVI), bimetallic Nano zero-valent iron-copper (Fe0- Cu), and fava bean activated carbon-supported with bimetallic Nano zero-valent iron-copper (AC-F e0-Cu) were prepared and characterized by DLS, FT-IR, XRD, and SEM. The influence of the synthesized adsorbents on the adsorption and removal of soluble anionic methyl orange (M.O) dye was investigated using UV-V spectroscopy. The influence of numerous operational parameters was studied at varied pH (3–9), time intervals (15–180 min), and dye concentrations (25–1000 ppm) to establish the best removal conditions. The maximum removal efficiency of M.O. using the prepared adsorbent materials reached about 99%. The removal efficiency is modeled using response surface methodology (RSM). The Bimetallic $$F{e}^{0}$$ F e 0 -Cu, the best experimental and predicted removal efficiency is 96.8% RE. For the H2SO4 chemical AC-$$F{e}^{0}$$ F e 0 -Cu, the best experimental and removal efficiency is 96.25% RE. The commercial AC-Fe0–Cu, the best experimental and predicted removal efficiency is 94.93%RE. This study aims to produce low-cost adsorbents such as Bimetallic Fe0-Cu, and Fava Bean Activated Carbon-Supported Bimetallic AC-Fe0-Cu to treat the industrial wastewater from the anionic methyl orange (M.O) dye and illustrate its ability to compete H2SO4 chemical AC-Fe0-Cu, and commercial AC-Fe0-Cu.