Coagulant recovery from water treatment plant sludge and reuse in post-treatment of UASB reactor effluent treating municipal wastewater

Enhancement of sludge dewaterability using combined technology of bioleaching and Fenton: Microscopic structure and hydrophilic/hydrophobic properties of sludge particles

Bioleaching and Fenton technology are commonly used preconditioning techniques for sludge dewatering. This study compared the dewatering mechanisms of different conditioning technologies. The results showed that bound water, specific resistance to filtration (SRF), and capillary suction time decreased from 3.95 g/g, 6.16 × 1012 m/kg, and 130.6 s to 3.15 g/g, 2.81 × 1011 m/kg, and 33 s, respectively, under combined treatment condition. Moreover, the free radicals, including ·OH, O2-·and Fe (Ⅳ), further damaged the cell structure, thus increasing the concentration of DNA in the S-EPS layer. This intense degradation sludge particle size decreased by 15.6% and significantly increased zeta potential. Under the combined technology, the α-helix and β-sheet decreased by 42.2% and 56.5%, respectively, destabilizing the spatial structure of proteins and promoting the release of bound water. In addition, the combined technology decreased (Ala/Lys) ratio in the TB-EPS layer by 67.6%, indicating the weakening of protein water-holding capacity. Moreover, the conversion of oxygen-containing compounds to nonpolar hydrocarbons increased the hydrophobicity of the sludge under a combined treatment, thus enhancing dewatering performance.

A vertical-flow constructed wetland-microalgal membrane photobioreactor integrated system for treating high-pollution-load marine aquaculture wastewater: A lab-scale study

Individual biological water treatment techniques often prove ineffective in removing accumulated high concentrations of nitrogen and phosphorus in the late stages of biofloc aquaculture. To address this issue, we integrated a previously developed autotrophic denitrification and nitrification integrated constructed wetland (ADNI-CW) with a microalgal membrane photobioreactor (MPBR). Under high nitrogen and phosphorus pollution loads in the influent, the standalone ADNI-CW system achieved removal rates of only 24.17 % ± 2.82 % for total nitrogen (TN) and 25.30 % ± 2.59 % for total phosphorus (TP). The optimal conditions for TN and TP degradation and microalgal biomass production in the Chlorella MPBR, determined using response surface methodology, were an inoculum OD680 of 0.394, light intensity of 161.583 μmol/m2/s, and photoperiod of 16.302 h light:7.698 h dark. Under the optimal operating conditions, the integrated ADNI-CW-MPBR system achieved remarkable TN and TP removal rates of 92.63 % ± 2.8 % and 77.46 % ± 8.41 %, respectively, and a substantial microalgal biomass yield of 54.58 ± 6.8 mg/L/day. This accomplishment signifies the successful achievement of efficient nitrogen and phosphorus removal from high-pollution-load marine aquaculture wastewater along with the acquisition of valuable microalgal biomass. A preliminary investigation of the microbial community composition and algal-bacterial interactions in different operational stages of the MPBR system revealed that unclassified_d__Bacteria, Chlorophyta, and Planctomycetes were predominant phyla. The collaborative relationships between bacteria and Chlorella surpassed competition, ensuring highly efficient nitrogen and phosphorus removal in the MPBR system. This study laid the foundation for the green and sustainable development of the aquaculture industry.

Evaluation of combined thermo-chemical processes for the treatment of landfill leachate using virgin and recovered FeCl3 coagulants

Sludge resulting from treatment of municipal waste landfill leachate contains suitable cationic substances such as Fe-based recovered coagulants which, if not recovered, can cause environmental problems. The present study aimed to maximise coagulant recoverability and investigate its potential reuse for the treatment of municipal waste landfill leachate. The study focused on establishing (i) the effect of mineral acids on leaching of Fe, (ii) the % of maximum recovery of Fe coagulant, (iii) the impact of ultrasound on recovery, and (iv) effectiveness of recovered coagulant when reused in coagulation-flocculation treatment of landfill leachate. Sulfuric acid outran hydrochloric acid in performance, with the acid leaching process leading to the recovery of 70.12% of Fe (acid concentration = 3.80 M, solid-to-liquid ratio = 8%, and heating time = 5 h). Subsequently, a developed acid leaching process was tested, which results showed that the highest rate of Fe recovery occurred without ultrasound treatment, meaning the use of it could reduce the recovery rate due to the increase in the iron (III) oxide-hydroxide [Fe(OH)3] sedimentation. Comparative experiments were undertaken with the recovered and virgin coagulants. These revealed that Fe-based recovered coagulant led to the 60.21% and 91.40% removal of COD and total suspended solid respectively, while the values of the COD and total suspended solid removal with the virgin FeCl3 were 7.66% and 6.42% lower than that of Fe under optimal conditions (dosage = 9.38 g/L, pH = 8.94, settling time = 52.9 min). The present study established that Fe recovered could be exploited as an eco-friendly coagulant to replace FeCl3 in the landfill leachate treatment.

Use of water treatment plant sludge in high-rate activated sludge systems: A techno-economic investigation

Coagulants such as aluminum sulfate (Al2(SO4)3 (alum)) and ferric chloride (FeCl3) used in water treatment plants (WTPs) led to the generation of sludge that is usually disposed to landfills. However, the utilization of WTP sludge is being encouraged by authorities to achieve sustainable development. This study aims to investigate WTP sludge utilization in a pilot-scale high-rate activated sludge (HRAS) system as a substitute for conventional coagulants. Based on jar tests, the iron sludge was selected for pilot-scale testing due to its superior ability to enhance the treatment efficiency of the HRAS process compared to alum sludge. Iron sludge addition (20.1 ± 1.6 mg dry sludge/L wastewater) slightly improved the removal efficiency of particulate chemical oxygen demand (pCOD) from 74 % to 81 % (p-value: 0.014). Iron sludge addition had a distinct effect on the sludge characteristics of the HRAS process. The average median particle size (d50) increased from 96 ± 3 to 163 ± 14 μm (p-value<0.00) with the addition of iron sludge, which improved the settleability of the HRAS process sludge. However, the biochemical methane potential (BMP) of the HRAS process sludge decreased by 8.9 % (p-value<0.00) after iron sludge addition. In a scenario analysis of WTP sludge use in a hypothetical HRAS plant, the effluent quality index (EQI), an indicator of environmental impact, was calculated and the cost related to the operation (the transfer and landfill disposal of WTP and HRAS process sludge, energy and chemical consumption of the HRAS plant) was estimated. As a result, using WTP sludge in the HRAS plant did not significantly affect the EQI of the plant but decreased overall cost by 11 %. The results showed that the use of WTP sludge as a coagulant in wastewater treatment could achieve mutual benefits for WTPs and WWTPs and have the potential to realize the circular economy model.

Black carbon derived PET plastic bottle waste and rice straw for sorption of Acid Red 27 dye: Machine learning approaches, kinetics, isotherm and thermodynamic studies

This study focuses on the probable use of PET waste black carbon (PETWBC) and rice straw black carbon (RSBC) as an adsorbent for Acid Red 27 (AR 27) adsorption. The prepared adsorbent is characterized by FE-SEM and FT-IR. Batch adsorption experiments were conducted with the influencing of different operational conditions namely time of contact (1-180 min), AR 27 concentration (5-70 mg/L), adsorbent dose (0.5-20 g/L), pH (2-10), and temperature (25-60°C). High coefficient value [PETWBC (R2 = 0.94), and RSBC (R2 = 0.97)] of process optimization model suggesting that this model was significant, where pH and adsorbent dose expressively stimulus removal efficiency including 99.88, and 99.89% for PETWBC, and RSBC at pH (2). Furthermore, the machine learning approaches (ANN and BB-RSM) revealed a good association between the tested and projected value. Pseudo-second-order was the well-suited kinetics, where Freundlich isotherm could explain better equilibrium adsorption data. Thermodynamic study shows AR 27 adsorption is favourable, endothermic, and spontaneous. Environmental friendliness properties are confirmed by desorption studies and satisfactory results also attain from real wastewater experiments. Finally, this study indicates that PETWBC and RSBC could be potential candidates for the adsorption of AR 27 from wastewater.

Oily cold rolling mill sludge conditioned by quicklime to improve dewatering performance: optimization and mechanism study

Dewatering is critical to oily cold rolling mill (CRM) sludge treatment. Therefore, finding an efficient, energy-saving, and applicable dewatering technology for oily CRM sludge is still urgent. This study investigated the performance of quicklime as a conditioning agent for oily CRM sludge conditioning and dewatering. The interactive effects of quicklime dosage, temperature, and time on filter cake's specific resistance to filtration (SRF) and the dewatering rate of oily CRM sludge were studied by response surface methodology (RSM). The optimal parameters for conditioning oily CRM sludge were quicklime dosage of 18.7%, temperature of 54 °C, and time of 43.3 min, which resulted in filter cake SRF of 0.50 × 1010 m/kg and dewatering rate of 61.2%. The viscosity of oily CRM sludge could be reduced by 90% after conditioned with quicklime, which caused by the neutralization or hydrolysis of high viscosity organic matter in the oil phase with quicklime to produce low viscosity organic matter. The study indicated the excellent performance of quicklime as a conditioning agent for oily CRM sludge treatment and provided an effective route for the recycling of the oily CRM sludge for steel production.

Realizable wastewater treatment process for carbon neutrality and energy sustainability: A review

Despite a quick shift of global goals toward carbon-neutral infrastructure, activated sludge based conventional systems inhibit the Green New Deal. Here, a municipal wastewater treatment plant (MWWTP) for carbon neutrality and energy sustainability is suggested and discussed based on realizable technical aspects. Organics have been recovered using variously enhanced primary treatment techniques, thereby reducing oxygen demand for the oxidation of organics and maximizing biogas production in biological processes. Meanwhile, ammonium in organic-separated wastewater is bio-electrochemically oxidized to N₂ and reduced to H₂ under completely anaerobic conditions, resulting in the minimization of energy requirements and waste sludge production, which are the main problems in activated sludge based conventional processes. The anaerobic digestion process converts concentrated primary sludge to biomethane, and H₂ gas recovered from nitrogen upgrades the biomethane quality by reducing carbon dioxide in biogas. Based on these results, MWWTPs can be simplified and improved with high process and energy efficiencies.

A comprehensive review on the coagulant recovery and reuse from drinking water treatment sludge

The main treatment unit in conventional systems for surface water is coagulation-flocculation (CF) process, which consumes huge quantities of coagulant, and produces large volume of sludge. The produced sludge is known as one of the components of water treatment sludge (WTS), which is considered as a global issue and hot topic require careful attention from the plant operators and sludge managers to be managed sustainably with applying an ecofriendly method. Among the suggested technologies, recovery and reuse of coagulants from WTS show the potential to decrease the waste disposal and chemicals usage for drinking water treatment significantly. So, this comprehensive review provides a useful insight into environmental and health problems of WTS, reports the sources, physicochemical properties of sludge, describes different sludge management methods by more focus on coagulant recovery (CR), which significantly point out the different aspects of WTS recovery and reuse, and eventually, economic evaluation of the CR process was also discussed. The results of this review confirm that coagulants can be recovered from WTS by different methods and also will be reused for multiple times in the removal of pollutants from water and wastewater. Moreover, the recovered coagulants can be used as building and construction materials, constructed wetlands substrate and other aims.

Simultaneous modelling of coagulant recovery and reuse by response surface methodology

Surface water from rivers, lakes, reservoirs etc. needs to be treated prior to municipal supplies. The treatment scheme includes coagulation, flocculation, sedimentation, filtration and finally disinfection process. Huge volume of sludge or waste is generated during the coagulation-flocculation. Disposal of the sludge so generated in the treatment plants require careful consideration for managing it sustainably and in an environment friendly manner. Constructive utilization of the inevitable waste may help in finding a sustainable solution to sludge disposal problems. Presently, response surface methodology (RSM) with central composite design (CCD) has been applied to simultaneously model coagulant recovery as well as reuse parameters. In order to simplify the process and increase the applicability, the effect of three significant variables, acid dose, sludge ratio, and recovered coagulant dose are studied. A second order regression model has been developed which gave the optimum combination of acid dose of 30 ml/L, sludge ratio of 1% and recovered coagulant dose of 12 ml/L for maximum turbidity removal. The predicted value of turbidity removal is 95.4%. In the confirmatory experiments, the turbidity removal value was observed to be about 96.2%, which is in good agreement with the predicted value. In addition to turbidity removal, it also helps to effectively remove other impurities from the raw water for it to meet the standards prescribed for potable supply. Thus, the regenerated alum or recovered coagulant has the potential to substitute the conventional coagulants, fully or partially at water treatment plants.

Preparation of carbon/Al2O3/nZVI magnetic nanophase materials produced from drinking water sludge for the removal of As(V) from aqueous solutions

Drinking water sludge (DWS) contains organic carbon and metal ions with the potential to prepare adsorbents. In this research, DWS was separated into two parts by acid leaching, i.e., an acid leaching carbonization sludge (ALCS) and an acid leaching solution. Iron and aluminum were extracted from the acid leaching solution and loaded onto ALCS by sedimentation and liquid-phase reduction to prepare a carbon/Al₂O₃/nZVI magnetic adsorption material (ALCS-Al-Fe). The optimum arsenic removal conditions, adsorption kinetics, and isotherm were determined, and the characteristics of the adsorbent ALCS-Al-Fe were investigated. The results showed that the composite exerted a favorable arsenic removal effect due to the electrostatic adsorption of nanometer zero-valent iron as well as ion exchange and complexation between the OH^- groups on the surface of ALCS-Al-Fe and As(V). The pH change had a slight effect on the adsorption capacity, while the common anions SO₄^2- and SiO₃^2- showed obvious inhibitory effects. Considering that alkalinity is beneficial to arsenic ion desorption, NaOH was used in desorbing to conduct 6 cycles of regeneration experiments, and the final removal rate could still reach 90.5%. Therefore, the concept of green development of preparing magnetic adsorbents by using whole component of DWS is significant to the exploitation of sludge recycling.

Aluminum leaching from water treatment sludge using hydrochloric acid and kinetic study

Water treatment sludge (WTS) is abundantly produced in the world; the waste contributes to the environmental problems. Therefore, for WTS utilization, aluminum leaching was employed using hydrochloric acid in this study. Al leaching efficiency increased from 72% to 80% as hydrochloric acid concentration increased from 1 to 4 M. Decreasing the particle size and increasing the temperature increased Al leaching efficiency. The proposed kinetic model revealed that the rate-controlling step followed a series of two leaching mechanisms: initially controlled by product-layer diffusion and then by a chemically controlled reaction. For instance, at 70 °C, the initial stage is well fitted by product-layer diffusion (R² = 0.87) compared to R² = 0.60 for chemical reaction; while for the second stage, R² = 0.95 was observed via chemical reaction compared to R² = 0.74 for product-layer diffusion. The activation energies in these two stages were 9.58 kJ/mol and 10.73 kJ/mol, respectively. The proposed model was well validated by using data from literature and thus will be useful for other applications of leaching and extraction processes.

Valorization of alum sludge via a pyrolysis platform using CO2 as reactive gas medium

In an effort to seek a new technical platform for disposal of drinking water treatment sludge (DWTS: alum sludge), pyrolysis of DWTS was mainly investigated in this study. To establish a more sustainable thermolytic platform for DWTS, this study particularly employed CO₂ as reactive gas medium. Thus, this study laid great emphasis on elucidating the mechanistic roles of CO₂ during the thermolysis of DWTS. A series of the TGA tests of DWTS in CO₂ in reference to N₂ revealed no occurrence of the heterogeneous reaction between CO₂ and the sample surface of DWTS. As such, at the temperature regime before initiating the Boudouard reaction (i.e., ≥700 °C), the mass decay patterns of DWTS in N₂ and CO₂ were nearly identical. However, the gaseous effluents from lab-scale pyrolysis of DWTS in CO₂ in reference to N₂ were different. In sum, the homogeneous reactions between CO₂ and volatile matters (VMs) evolved from the thermolysis of DWTS led to the enhanced generation of CO. Also, CO₂ suppressed dehydrogenation of VMs. Such the genuine mechanistic roles of CO₂ in the thermolysis of DWTS subsequently led to the compositional modifications of the chemical species in pyrolytic oil. Furthermore, the biochar composite was obtained as byproduct of pyrolysis of DWTS. Considering that the high content of Al₂O₃ and Fe-species in the biochar composite imparts a strong affinity for As(V), the practical use of the biochar composite as a sorptive material for arsenic (V) was evaluated at the fundamental levels. This work reported that adsorption of As(V) onto the biochar composite followed the pseudo-second order model and the Freundlich isotherm model.

Modelling dye removal by adsorption onto water treatment residuals using combined response surface methodology-artificial neural network approach

In this study, response surface methodology (RSM)-artificial neural network (ANN) approach was used to optimise/model disperse dye removal by adsorption using water treatment residuals (WTR). RSM was first applied to evaluate the process using three controllable operating parameters, namely WTR dose, initial pH (pH_initial) and dye concentration, and optimal conditions for colour removal were determined. In the second step, the experimental results of the design data of RSM were used to train the neural network along with a non-controllable parameter, the final pH (pH_final). The trained neural networks were used for predicting the colour removal. A colour removal of 52.6 ± 2.0% obtained experimentally at optimised conditions (pH_initial 3.0, adsorbent dose 30 g/L and dye concentration 75 mg/L) was comparable to 52.0% and 52.2% predicted by RSM and RSM-ANN, respectively. This study thus shows that optimising/predicting the colour removal process using the RSM-ANN approach is possible, and it also indicates that adsorption onto WTR could be used as a primary treatment for removal of colour from dye wastewater.

Optimization of aluminium recovery from water treatment sludge using Response Surface Methodology

For decades, water treatment plants in Malaysia have widely employed aluminium-based coagulant for the removal of colloidal particles in surface water. This generates huge amount of by-product, known as sludge that is either reused for land applications or disposed to landfills. As sludge contains high concentration of aluminium, both can pose severe environmental issues. Therefore, this study explored the potential to recover aluminium from water treatment sludge using acid leaching process. The evaluation of aluminium recovery efficiency was conducted in two phases. The first phase used the one factor at a time (OFAT) approach to study the effects of acid concentration, solid to liquid ratio, temperature and heating time. Meanwhile, second phase emphasized on the optimization of aluminium recovery using Response Surface Methodology (RSM). OFAT results indicated that aluminium recovery increased with the rising temperature and heating time. Acid concentration and solid to liquid ratio, however, showed an initial increment followed by reduction of recovery with increasing concentration and ratio. Due to the solidification of sludge when acid concentration exceeded 4 M, this variable was fixed in the optimization study. RSM predicted that aluminium recovery can achieve 70.3% at optimal values of 4 M, 20.9%, 90 °C and 4.4 h of acid concentration, solid to liquid ratio, temperature and heating time, respectively. Experimental validation demonstrated a recovery of 68.8 ± 0.3%. The small discrepancy of 2.2 ± 0.4% between predicted and validated recovery suggests that RSM was a suitable tool in optimizing aluminium recovery conditions for water treatment sludge.

Using photocatalyst powder to enhance the coagulation and sedimentation of cyanobacterial cells and enable the sludge to be self-purified under visible light

Removing harmful cyanobacteria intact by coagulation can prevent cell lysis and toxin release, which provides many benefits for drinking water production, including reduction of the burden on subsequent processes and guaranteeing the water quality. But the electronegativity and buoyancy of cyanobacterial cells make them settle slowly and their accumulation and concentration in flocs would still have severe adverse effects. In this study, we introduced a photocatalyst powder to act as a ballasting agent in the coagulation process and to degrade the cells and cyanotoxins during sludge storage. Results showed that adding N-TiO₂ would decrease the coagulant dose to half of the conventional value, and also allow Microcystis aeruginosa cells to completely settle within 10 min. During sludge storage, the algal cells, cyanotoxins and other organics in sludge would be degraded to safe levels after 32 h' visible-light irradiation. Meanwhile, the N-TiO₂, water and some of the coagulant in purified sludge will be directly and safely reused. Thus, this is an environmentally friendly and cost-effective technology which incorporates photocatalyst in algal flocs to enhance coagulation and sedimentation and to enable the sludge produced to be self-purified under visible-light.

Carbon and Phosphorus Removal from Primary Municipal Wastewater Using Recovered Aluminum

In this work, recovery of aluminum from coagulated primary sludge and its reuse potential as secondary coagulant were investigated. The recovery process consisted of releasing the particle-bound aluminum from primary sludge by acidification (HCl or H₂SO₄), followed by separation using centrifugation for dissolved coagulant recovery. The recovered coagulant was then reused for treating primary wastewater and overall coagulation efficiency was determined. While with fresh alum, the removal efficiencies of total suspended solids, chemical oxygen demand, total phosphorus, and total nitrogen were 85%, 65%, 80% and 33%, respectively, a drop in removal efficiency of total suspended solids and chemical oxygen demand was observed for recovered aluminum (85-60% and 65-50%, respectively). Nitrogen concentration remained almost constant with each cycle, while phosphorus in the effluent increased by 1 mg/L and 3 mg/L in the first and second cycle, respectively. Precipitation of various aluminum species was modeled for determining the recovery potential of aluminum at low pH. Preliminary cost analysis indicates that optimum recovery of aluminum occurred at a pH of 1.5 for both acids. Struvite precipitation effectively removed increased phosphorus solubilized by acidification at the end of second cycle, however, it also decreased the amount of aluminum available for recycle.

Comprehensive reuse of drinking water treatment residuals in coagulation and adsorption processes

While drinking water treatment residuals (DWTRs) inevitably lead to serious problems due to their huge amount of generation and limitation of landfill sites, their unique properties of containing Al or Fe contents make it possible to reuse them as a beneficial material for coagulant recovery and adsorbent. Hence, in the present study, to comprehensively handle and recycle DWTRs, coagulant recovery from DWTRs and reuse of coagulant recovered residuals (CRs) were investigated. In the first step, coagulant recovery from DWTRs was conducted using response surface methodology (RSM) for statistical optimization of independent variables (pH, solid content, and reaction time) on response variable (Al recovery). As a result, a highly acceptable Al recovery of 97.5 ± 0.4% was recorded, which corresponds to 99.5% of the predicted Al recovery. Comparison study of recovered and commercial coagulant from textile wastewater treatment indicated that recovered coagulant has reasonable potential for use in wastewater treatment, in which the performance efficiencies were 68.5 ± 2.1% COD, 97.2 ± 1.9% turbidity, and 64.3 ± 1.0% color removals at 50 mg Al/L. Subsequently, in a similar manner, RSM was also applied to optimize coagulation conditions (Al dosage, initial pH, and reaction time) for the maximization of real cotton textile wastewater treatment in terms of COD, turbidity, and color removal. Overall performance revealed that the initial pH had a remarkable effect on the removal performance compared to the effects of other independent variables. This is mainly due to the transformation of metal species form with increasing or decreasing pH conditions. Finally, a feasibility test of CRs as adsorbent for phosphate adsorption from aqueous solution was conducted. Adsorption equilibrium of phosphate at different temperatures (10-30 °C) and initial levels of pH (3-11) indicated that the main mechanisms of phosphate adsorption onto CRs are endothermic and chemical precipitation; the surfaces are energetically heterogeneous for adsorbing phosphate.

Dual purpose recovered coagulant from drinking water treatment residuals for adjustment of initial pH and coagulation aid in electrocoagulation process

The present study is focused on the application of recovered coagulant (RC) by acidification from drinking water treatment residuals for both adjusting the initial pH and aiding coagulant in electrocoagulation. To do this, real cotton textile wastewater was used as a target pollutant, and decolorization and chemical oxygen demand (COD) removal efficiency were monitored. A preliminary test indicated that a stainless steel electrode combined with RC significantly accelerated decolorization and COD removal efficiencies, by about 52% and 56%, respectively, even at an operating time of 5 min. A single electrocoagulation system meanwhile requires at least 40 min to attain the similar removal performances. Subsequently, the interactive effect of three independent variables (applied voltage, initial pH, and reaction time) on the response variables (decolorization and COD removal) was evaluated, and these parameters were statistically optimized using the response surface methodology. Analysis of variance showed a high coefficient of determination values (decolorization, R(2) = 0.9925 and COD removal, R(2) = 0.9973) and satisfactory prediction second-order polynomial quadratic regression models. Average decolorization and COD removal of 89.52% and 94.14%, respectively, were achieved, corresponding to 97.8% and 98.1% of the predicted values under statistically optimized conditions. The results suggest that the RC effectively played a dual role of both adjusting the initial pH and aiding coagulant in the electrocoagulation process.

Selective oxidative degradation of toluene for the recovery of surfactant by an electro/Fe²⁺/persulfate process

An electro/Fe(2+)/persulfate process has been conducted for toluene removal from surfactant (SDS) flushing solution, and the pseudo-second-order reaction rate constant (k2 value) of toluene removal has been optimized by a response surface methodology (RSM). The results indicated that in this process, the reaction between persulfate and externally added Fe(2+) generates sulfate-free radicals, and at the same time, Fe(2+) is electro-regenerated at the cathode by the reduction of Fe(3+). RSM based on Box-Behnken design (BBD) has been applied to analyze the experimental variables, of which the concentrations of persulfate and Fe(2+) showed a positive effect on the rate constant of toluene removal, whereas the concentration of SDS showed a negative effect. The interactions between pairs of variables proved to be significant, such as between SDS, persulfate, and Fe(2+) concentrations. ANOVA results confirmed that the proposed models were accurate and reliable for analysis of the variables of the electro/Fe(2+)/persulfate process. The shapes of the 3D response surfaces and contour plots showed that the SDS, persulfate, and Fe(2+) concentrations substantially affected the k2 value of toluene removal. The results indicated that increasing persulfate or Fe(2+) concentration increased the k2 value, whereas increasing SDS concentration decreased the k2 value. The reaction intermediates have been identified by GC-MS, and a plausible degradation pathway for toluene degradation is proposed.