This work focuses on the optimization of the experimental factors affecting adsorptive desulfurization process in a continuous flow system using response surface methodology (RSM). To achieve that, AC-Ni was prepared by loading nickel nanoparticles on activated carbon (AC). Then, AC-Ni was evaluated for adsorptive desulfurization of DBT from model fuel using a flow system. A response surface method was applied to determine the significant factors affecting the adsorption of dibenzothiophene. A face centred central composite design (CCD) was used to statistically visualize the complex interactions of concentration, column length, dosage, and flow rate on the adsorption of dibenzothiophene, The factors having the poorest combinations in our CCD achieved a 70% removal of DBT based on the experimental analysis. However, to attain a 96% removal of DBT from a model fuel having an initial concentration of 59 ppm, a high dosage of the adsorbent (0.5 g), and a column length of 11 cm were required. In contrast, a flow rate of 50 r.p.m., and a contact time of five minutes were sufficient to achieve an exceptional removal. The optimized factors are highlighted with a composite desirability value of 0.92861. The synthesized adsorbent is relatively cheap and of double benefits to the environment solving waste management and desulfurization issues simultaneously. (C) 2016 Elsevier B.V. All rights reserved.