Effect of polarity shift on the performance of electrocoagulation process for the treatment of produced water

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.

Electrochemical-based processes for produced water and oily wastewater treatment: A review

The greatest volume of by-products produced in oil and gas recovery operations is referred to as produced water and increasing environmental concerns and strict legislations on discharging it into the environment cause to more attention for focusing on degradation methods for treatment of produced water especially electrochemical technologies. This article provides an overview of electrochemical technologies for treating oily wastewater and produced water, including: electro-coagulation, electro-Fenton, electrochemical oxidation and electrochemical membrane reactor as a single stage and combination of these technologies as multi-stage treatment process. Many researchers have carried out experiments to examine the impact of various factors such as material (i.e, electrode material) and operational conditions (i.e., potential, current density, pH, electrode distance, and other factors) for organic elimination to obtain the high efficiency. Results of each method are reviewed and discussed according to these studies, comprehensively. Furthermore, several challenges need to be overcome and perspectives for future study are proposed for each method.

Effect of polarity reversal on floc formation and rheological properties of a sludge formed by the electrocoagulation process

Anode fouling is one of the key limiting factors to the widespread application of electrocoagulation (EC) for treatment of different types of contaminated water. Promising mitigation strategy to fouling is to operate the process under polarity reversal (PR) instead of direct current (DC). However, the PR operation comes at the cost of process complexity due to the alternation of electrochemical and chemical reactions. In this study, we systematically investigated the link between evolving fouling layer during DC and PR close to iron and aluminum electrodes and morphological and rheological properties of the formed sludge. By operando visualization of EC process, we demonstrate that during PR operation, precipitation of the iron and aluminum species occurs close to the anode interface, resulting in flocs with higher porosity and lower density than those formed under DC conditions. However, rheological investigation revealed that the PR conditions resulted in a sludge with more pronounced solid-like signature, but this enhancement in its viscoelastic properties is closely related to a period of the current's polarity reversal. We attribute this unexpected result to higher shear rate and collision of particles during PR conditions.

Polymer-flooding produced water treatment using an electro-hybrid ozonation-coagulation system with novel cathode membranes targeting alternating filtration and in situ self-cleaning

Polymer-flooding produced water is more difficult to treat for reinjection compared with normal produced water because of the presence of residual hydrolyzed polyacrylamide (HPAM). A novel cathode membrane integrated electro-hybrid ozonation-coagulation (CM-E-HOC) process was proposed for the treatment of polymer-flooding produced water. This process achieved in situ self-cleaning by generated microbubbles in the cathode membrane. The CM-E-HOC process achieved a higher suspended solid (SS), turbidity and PAM removal efficiency than the CM-EC process. The SS in the CM-E-HOC effluent was ≤ 20 mg/L SS, which met the reinjection requirements of Longdong, Changqing Oilfield, China (Q/SYCQ 08,011-2019) at different current densities (3, 5 and 10 mA/cm²). The CM-E-HOC process greatly mitigated both reversible and irreversible membrane fouling. Therefore, excellent flux recovery was obtained at different in situ self-cleaning intervals during the CM-E-HOC process. Furthermore, alternating filtration achieved continuous water production during the CM-E-HOC process. On one hand, the effective removal of aromatic protein-like substances and an increase in oxygen-containing functional groups were achieved due to the enhanced oxidation ability of the CM-E-HOC process, which decreased membrane fouling. On the other hand, the CM-E-HOC process showed improved coagulation performance because of the increased oxygen-containing functional groups and polymeric Fe species. Therefore, larger flocs with higher fractal dimensions were generated, and a looser and more porous cake layer was formed on the membrane surface during the CM-E-HOC process. Consequently, the CM-E-HOC process exhibited better in situ self-cleaning performance and lower filtration resistance than the CM-EC process.

The role of the current waveform in mitigating passivation and enhancing electrocoagulation performance: A critical review

Electrocoagulation (EC) can be an efficient alternative to existing water and wastewater treatment methods due to its eco-friendly nature, low footprint, and facile operation. However, the electrodes applied in the EC process suffer from passivation or fouling, an issue resulting from the buildup of poorly conducting materials on the electrode surface. Indeed, such passivation gives rise to various operational problems and restricts the practical implementation of EC on a large scale. Therefore, it has been suggested that using pulsed direct current (PDC), alternating pulse current (APC), and sinusoidal alternating current (AC) waveforms in EC as alternatives to conventional direct current (DC) can help mitigate passivation and alleviate its associated detrimental effects. This paper presents a critical review of the impact of the current waveform on the EC process towards the capabilities of the PDC, APC, and AC waveforms in de-passivation and performance enhancement while comparing them to the conventional DC. Additionally, current waveform parameters influencing the surface passivation of electrodes and process efficiency are elaborately discussed. Meanwhile, the performance of the EC process is evaluated under different current waveforms based on pollutant removal efficiency, energy consumption, electrode usage, sludge production, and operating cost. The proper current waveforms for treating various water and wastewater matrices are also explained. Finally, concluding remarks and outlooks for future research are provided.

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.

A critical review in electrocoagulation technology applied for oil removal in industrial wastewater

EC process, which stands for Electrocoagulation, is considered a widespread wastewater remediation method that is investigated widely for an extensive variety of wastewater resources, based on its flexibility, easy setup, eco-friendly nature, and low footprint. The critical operative factors in the EC process and the crucial relation between EC and the typical chemical coagulation approach had been thoroughly evaluated because they are the main variables that govern the process of contaminant elimination. As a result, the EC process requires further investigations for scale-up simulations in the manufacturing scopes and optimization of operational parameters. Furthermore, the current paper studies the novel integrated separation methods with the combined EC process and also their limitations for improved wastewater remediation process for cleaner wastes, recycling processes, and water recovery. In this paper, the EC enhancement processes toward oil removal from wastewater have been reviewed which includes a concise representation of the source and features of oily wastewater. Additionally, the advanced remediation methods for oil-contained wastewater and the electrocoagulation process are presented. This review summarized the present utilization of electrocoagulation to eliminate oil from wastewater. Besides the process optimization and modeling investigations, the parameters that significantly affect the electrocoagulation remediation effectiveness are evaluated. Finally, the cutting-edge and sophisticated methods of electrocoagulation process for oil removal are presented.

A critical review of state-of-the-art electrocoagulation technique applied to COD-rich industrial wastewaters

Electrocoagulation (EC) is one of the emerging technologies in groundwater and wastewater treatment as it combines the benefits of coagulation, sedimentation, flotation, and electrochemical oxidation processes. Extensive research efforts implementing EC technology have been executed over the last decade to treat chemical oxygen demand (COD)-rich industrial wastewaters with the aim to protect freshwater streams (e.g., rivers, lakes) from pollution. A comprehensive review of the available recent literature utilizing EC to treat wastewater with high COD levels is presented. In addition, recommendations are provided for future studies to improve the EC technology and broaden its range of application. This review paper introduces some technologies which are often adopted for industrial wastewater treatment. Then, the EC process is compared with those techniques as a treatment for COD-rich wastewater. The EC process is considered as the most privileged technology by different research groups owing to its ability to deal with abundant volumes of wastewater. After, the application of EC as a single and combined treatment for COD-rich wastewaters is thoroughly reviewed. Finally, this review attempts to highlight the potentials and limitations of EC. Related to the EC process in batch operation mode, the best operational conditions are found at 10 V and 60 min of voltage and reaction time, respectively. These last values guarantee high COD removal efficiencies of > 90%. This review also concludes that considerably large operation costs of the EC process appears to be the serious drawback and renders it as an unfeasible approach for handling of COD rich wastewaters. In the end, this review has attempted to highlights the potential and limitation of EC and suggests that vast notably research in the field of continuous flow EC system is essential to introduce this technology as a convincing wastewater technology.