Surplus biological sludge can be used as a low-cost adsorbent in the removal of heavy metal from wastewater. A three-zone contact-settling pilot plant was designed and operated to maintain continuous sludge-metal solution contact and subsequent separation of solid-liquid phases, all in the same vessel. Mild agitation was used to ensure good contact between Cu(II) and sludge without impairing solid-liquid separation. Heavy metal removal efficiency was largely unaffected by an increase in the Cu/sludge feed ratio as long as metal binding sites in the sludge remained unsaturated. Maximum metal uptake (75 mg Cu(II) g(-1) of total solids in the sludge) was found for Cu/sludge feed ratios greater than or equal to 90 mg Cu(II) g(-1) of total solids. Pilot plant metal sorption uptake at different operational conditions correlated well. with the calculated values from batch equilibrium adsorption isotherms. The amount of Cu(II) adsorbed on sludge influenced the degree of clarification due to the flocculating effect of Cu(II). Under operational conditions, a high degree of heavy metal removal and efficient clarification were achieved. Pilot plant operation at a Cu/sludge feed ratio around 90 mg Cu(II) g(-1) of total solids allowed efficient use of the biosorbent and high heavy metal removal efficiency in addition to a good quality metal-free effluent in terms of low total suspended solids content.