Modeling of the electrocoagulation process: A study on the mass transfer of electrolysis and hydrolysis products

A mechanistic mathematical model for the treatment of synthetic oil-field wastewater (produced water) by electrocoagulation process using aluminium electrodes

Produced water (PW) is the largest by-product that comes out of the oil wells during oil and gas (O&G) field exploration. PW contains high-salt concentration along with other organic and inorganic components; therefore, PW must be treated before disposal. Electrocoagulation (EC) is an effective treatment method to remove pollutants from PW which has been the focus of many experimental studies; however, a mathematical model specifically for PW treatment by EC has not been developed yet. In this work, a comprehensive mathematical model has been developed to elucidate the role of EC operating parameters on the PW treatment performance and determine the mechanism for COD (Chemical Oxygen Demand) removal. The present model considers and identifies the dominant Al-hydroxy complex species and their contribution to the COD removal from synthetic PW samples by estimating their rate constants and comparing their magnitudes and investigates multi-scale modelling of the EC reactor. The influence of working parameters such as current density, initial pH, interelectrode distance, mixing speed and solution volume of PW on Al coagulant production and COD removal was investigated and modelled. The study estimates the rate constants of the reactions taking place for COD removal by EC process and by comparing their magnitudes identifies the dominant reactions and coagulant species involved in the process. The mathematical model prediction of COD removal fits well with the experimental data at 10 mA cm-2, 15 mA cm-2 and 20 mA cm-2 current density with R2 value of 0.96, 0.97 and 0.92, respectively and for dissolved Al concentration R2 value of 0.96, 0.99, and 0.97, respectively. The simulated results reproduced a good fit at initial pH of 6.1, 7.3 and 8.6 with R2 value of 0.92, 0.96 and 0.98, respectively for COD removal. The mathematical model and the experimental results showed the role of dominant Al-hydroxy complex species such asAl OH 2 + ,Al OH 2 + , Al OH 3 ,Al 2 OH 2 + 4 andAl OH 4 - in controlling the COD removal process. Under different operating conditions considered in the study, the model also predicted the COD removal performance of the EC reactors at different reactor volumes with R2 value of 0.96 for higher solution volume and larger reactor. The model presented and rate constants determined in the study will provide a theoretical basis for designing, scaling up and operating the EC reactor for oil-field PW treatment.

A comprehensive review on green perspectives of electrocoagulation integrated with advanced processes for effective pollutants removal from water environment

The rapidly expanding global energy demand is forcing a release of regulated pollutants into water that is threatening human health. Among various wastewater remediating processes, electrocoagulation (EC) has scored a monumental success over conventional processes because it combines coagulation, sedimentation, floatation and electrochemical oxidation processes that can effectively decimate numerous stubborn pollutants. The EC processes have gained some attention through various academic and industrial publications, however critical evaluation of EC processes, choices of EC processes for various pollutants, process parameters, mechanisms, commercial EC technologies and performance enhancement via other degradation processes (DPs) integration have not been comprehensively covered to date. Therefore, the major objective of this paper is to provide a comprehensive review of 20 years of literature covering EC fundamentals, key process factors for a reactor design, process implementation, current challenges and performance enhancement by coupling EC with pivotal pollutant DPs including, electro/photo-Fenton (E/P-F), photocatalysis, sono-chemical treatment, ozonation, indirect electrochemical/advanced oxidation (AO), and biosorption that have substantially reduced metals, pathogens, toxic compound BOD, COD, colors in wastewater. The results suggest that the optimum treatment time, current density, pulse frequency, shaking speed and spaced electrode improve the pollutants removal efficiency. An elegant process design can prevent electrode passivation which is a critical limitation of EC technology. EC coupling (up or downstream) with other DPs has resulted in the removal of organic pollutants and heavy metals with a 20% improved efficiency by EC-EF, removal of 85.5% suspended solid, 76.2% turbidity, 88.9% BOD, 79.7% COD and 93% color by EC-electroflotation, 100% decolorization by EC-electrochemical-AO, reduction of 78% COD, 81% BOD, 97% color by EC-ozonation and removal of 94% ammonia, 94% BOD, 95% turbidity, >98% phosphorus by aerated EC and peroxicoagulation. The major wastewater purification achievements, future potential and challenges are described to model the future EC integrated systems.

Tangential effluent inlet in a cylindrical electrocoagulation reactor containing curved electrodes, and its use in crude oil in water treatment

A continuous electrocoagulation reactor, with curved electrodes, polarity switch, and cylindrical geometry, was used for emulsified crude oil in water separation. Apparatus novelty consists of an inlet arranged to promote a circular flow regime. The effects of flow rate (2 and 6 mL.s^-1), electrical current (2 and 4 A), and distance between electrodes (1.5 and 2.5 cm) were investigated using a full factorial design and statistical analysis. Using 6 mL.s^-1 flow rate, 2 A electric current and 2.5 cm electrode distance; 86% oil removal was obtained at a pH < 9.0. For this configuration, the system will process 21.6 L of oily emulsion while consuming 6.92 Wh. Oil removal increased with flow rate, a novel characteristic created by the unusual geometry of the system.

Removal of inorganic pollutants using electrocoagulation technology: A review of emerging applications and mechanisms

Electrocoagulation (ECoag) technique has shown considerable potential as an effective method in separating different types of pollutants (including inorganic pollutants) from various sources of water at a lower cost, and that is environmentally friendly. The EC method's performance depends on several significant parameters, including current density, reactor geometry, pH, operation time, the gap between electrodes, and agitation speed. There are some challenges related to the ECoag technique, for example, energy consumption, and electrode passivation as well as its implementation at a larger scale. This review highlights the recent studies published about ECoag capacity to remove inorganic pollutants (including salts), the emerging reactors, and the effect of reactor geometry designs. In addition, this paper highlights the integration of the ECoag technique with other advanced technologies such as microwave and ultrasonic to achieve higher removal efficiencies. This paper also presents a critical discussion of the major and minor reactions of the electrocoagulation technique with several significant operational parameters, emerging designs of the ECoag cell, operating conditions, and techno-economic analysis. Our review concluded that optimizing the operating parameters significantly enhanced the efficiency of the ECoag technique and reduced overall operating costs. Electrodes geometry has been recommended to minimize the passivation phenomenon, promote the conductivity of the cell, and reduce energy consumption. In this review, several challenges and gaps were identified, and insights for future development were discussed. We recommend that future studies investigate the effect of other emerging parameters like perforated and ball electrodes on the ECoag technique.

Electrocoagulation Process: An Approach to Continuous Processes, Reactors Design, Pharmaceuticals Removal, and Hybrid Systems—A Review

The electrocoagulation (EC) process has been widely studied in recent years to remove a wide range of contaminants present in different types of water: fluorides, arsenic, heavy metals, organic matter, colorants, oils, and recently, pharmaceutical compounds. However, most of the studies have been aimed at understanding the process factors that have the most significant effect on efficiency, and these studies have been mainly on a batch process. Therefore, this review is focused on elucidating the current state of development of this process and the challenges it involves transferring to continuous processes and the recent exploration of its potential use in the removal of pharmaceutical contaminants and its implementation with other technologies.

Combined metal/air fuel cell and electrocoagulation process: Energy generation, flocs production and pollutant removal

Electrocoagulation (EC) which is characterized by in-situ generation of highly absorbable hydroxide flocs, is an environmentally friendly process for treating heavy metal ions and toxic organic wastewater. In order to decrease EC's energy consumption, a combined metal/air FC-EC process which contains two successive parts: metal/air fuel cell (FC) and electrocoagulation (EC) was studied with the consideration of hydroxide flocs production, pollutant removal and energy generation analysis. For the combined iron/air FC-EC process, the porous nickel cathode which has a good performance in high polarization zone was selected as the ideal air cathode. It was found that iron/air FC-EC with acid electrolyte condition has a high energy generation (as high as 20% EC energy consumption). The energy generation increases with iron/air FC time. Also energy generation increases with wastewater's conductivity. Beside the energy generation, the iron/air fuel cell generate extra coagulants Fe²⁺ for the subsequent EC process. The coagulants generated from iron/air FC and EC process together have further spontaneous hydrolysis reactions with the OH^- to form hydroxide flocs, which are beneficial for a rapid adsorption and pollutant trapping. Compared with EC process, iron/air (or Al/air) FC-EC process shows lower energy consumption and high removal efficiency for treating acid wastewater.

Enhanced removal of copper by electroflocculation and electroreduction in a novel bioelectrochemical system assisted microelectrolysis

The idea is immensely attractive if copper ions can be completely removed in wastewater. In this study, a novel bioelectrochemical system assisted microelectrolysis was developed for the enhanced removal of copper. One abandoned aluminium was used as anode and graphite/activated carbon as biological anode, and a bifunctional catalytic conductive membrane as cathode. Under the combined action of electroreduction and electroflocculation, copper ions directly pumped into the cathode chamber were efficiently treated, and organic matter was synchronously removed (Copper ions >99.9%, TOC >98.2%, COD >97.9%, NH₄⁺-N >94.5% and TP >94.9%). The reactions of primary batteries and microelectrolysis in anode chamber significantly enhanced the self-production capacity of BES (maximum power density of 2250 mW m^-3 at current density 10.65 mA m^-2, maximum cell voltage of 1.4 V). The results confirmed the application potential of bioelectrochemical system assisted microelectrolysis for the removal of copper.

Numerical simulation and exploration of electrocoagulation process for arsenic and antimony removal: Electric field, flow field, and mass transfer studies

In order to intuitively and clearly evaluate the potential and current distribution, the fluid flow and mixing, as well as mass transfer involved in electrocoagulation process for As and Sb removal, numerical simulation of electric field, flow field and mass transfer were constructed by Comsol Multiphysics and verified by experiments. Results displayed that the primary current and potential distribution were improved by changing electrode distance or adding insulator in a batch reactor. When configuration 2 and 2 cm electrode distance were applied, a more uniform primary current distribution and higher electrode current efficiency were obtained. In a continuous flow reactor, the increase of flow rate resulted in the left shift of the peak in residence time distribution curve, gradual decrease of the tailing area, reduction of the stagnation zone, and more uniform mixing of the fluid. However, higher than 0.043 L/min was unfavorable to the formation of flocs and its effective combination with pollutants. According to the simulation of mass transfer, at the initial stage, the rate of electrolysis/hydrolysis was greater than that of mass transfer. Fe²⁺, OH^-, and Fe(OH)₂ were primarily concentrated on the anode, cathode, and between the two electrodes, respectively. Under the action of electromigration, diffusion and convection, the concentration distribution of Fe(OH)₂ increased at the direction of streamline. The concentration of Fe²⁺ and OH^- achieved the minimum value at the outlet. However, Fe(OH)⁺ concentration and distribution were hardly affected by the treatment time, and once generated, immediately proceed to the next hydrolysis reaction.

A novel bio-electrochemical system with sand/activated carbon separator, Al anode and bio-anode integrated micro-electrolysis/electro-flocculation cost effectively treated high load wastewater with energy recovery

A novel bio-electrochemical system (BES) was developed by integrating micro-electrolysis/electro-flocculation from attaching a sacrificing Al anode to the bio-anode, it effectively treated high load wastewater with energy recovery (maximum power density of 365.1 mW/m³ and a maximum cell voltage of 0.97 V), and achieving high removals of COD (>99.4%), NH₄⁺-N (>98.7%) and TP (>98.6%). The anode chamber contains microbes, activated carbon (AC)/graphite granules and Al anode. It was separated from the cathode chamber containing bifunctional catalytic and filtration membrane cathode (loaded with Fe/Mn/C/F/O catalyst) by a multi-medium chamber (MMC) filled with manganese sand and activated carbon granules, which replaced expensive PEM and reduced cost. An air contact oxidation bed for aeration was still adopted before liquid entering the cathode chamber. micro-electrolysis/electro-flocculation helps in achieving high removal efficiencies and contributes to membrane fouling migration. The increase of activated carbon in the separator MMC increased power generation and reduced system electric resistance.