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

Electrochemical treatment of wastewater containing urea-formaldehyde and melamine-formaldehyde

The wastewater containing urea-formaldehyde (UF) and melamine-formaldehyde (MF) from the medium-density fiberboard (MDF) lamination factory disposed into the waterbodies adversely affects human health and aquatic life. Therefore, its treatment before discharge is necessary. Researchers have used various techniques to treat this type of wastewater in the past, but none have tried electrochemical (EC). However, EC can potentially remove pollutants such as chemical oxygen demand (COD), total organic carbon (TOC), formaldehyde (FA), total nitrogen (TN), nitrogen nitrate (NO3-N), and other hydrocarbons. Hence, this study uses the EC technique to treat wastewater containing UF and MF with aluminium electrodes. The experiments were run in batch mode with a 250 mL working volume in a 500 mL Pyrex glass beaker using a variable DC power supply (0-30 V and 0-5 A). The impacts of various parameters, including reaction time (RT) 30-240 min, current density (CD) 8.66-51.94 mA/cm2, inter-electrode distance (IED) 1-2 cm, and mixing speed in the range of 60-120 rpm were examined to achieve the best pollutant removals. The best removal percentage was reached at the optimized conditions of 150 min RT, 43.28 mA/cm2 CD, 1.5 cm IED, and 80 rpm: 81.1% TOC, 61.5% COD, 76.7% TN, 28.3% NO3-N, and 55.2% FA. During the EC process, electrodes and energy consumption were estimated at around 2.367 (g/L) and 0.18 (kWh/L), respectively. A kinetic analysis was also carried out to determine the pollutant's removal trend. This study concluded that the pseudo-first-order kinetic model was the best fit for removing TOC and FA with regression coefficients of 0.96 and 0.83, respectively.

Biodegradability enhancement of waste lubricating oil regeneration wastewater using electrocoagulation pretreatment

As a sustainable management of fossil fuel resources and ecological environment protection, recycling used lubricating oil has received widespread attention. However, large amounts of waste lubricating-oil regeneration wastewater (WLORW) are inevitably produced in the recycling process, and challenges are faced by traditional biological treatment of WLORW. Thus, this study investigated the effectiveness of electrocoagulation (EC) as pretreatment and its removal mechanism. The electrolysis parameters (current density, initial pH, and inter-electrode distance) were considered, and maximal 60.06% of oil removal was achieved at a current density of 15 mA/cm2, initial pH of 7, and an inter-electrode distance of 2 cm. The dispersed oil of WLORW was relatively easily removed, and most of the oil removal was contributed by emulsified oil within 5-10 μm. Gas chromatography-mass spectrometry (GC-MS) analysis revealed that effective removal of the biorefractory organic compounds could contribute to the improvement of biodegradability of WLORW. Thus, the 5-day biochemical oxygen demand/chemical oxygen demand ratio (BOD5/COD) was significantly enhanced by 4.31 times, which highly benefits future biological treatment. The routes of WLORW removal could be concluded as charge neutralization, adsorption bridging, sweep flocculation, and air flotation. The results demonstrate that EC has potential as an effective pretreatment technology for WLORW biological treatment.

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.

A novel recycling way of blast furnace dust from steelworks: Electrocoagulation coupled micro-electrolysis system in indigo wastewater treatment

In this study, a novel electrocoagulation electrode, based on blast furnace dust (BFD) from steelworks waste, was prepared for indigo wastewater treatment, and the performance was compared with different ratios of Fe-C composite electrodes. The BFD electrode exhibited great electrochemical performance and removal effect. The presence of Fe-C micro-electrolysis in the electrocoagulation system of the BFD electrode was demonstrated by FT-IR, Raman, ESR, and quenching experiments. Density Functional Theory (DFT) calculations further demonstrated that the iron-carbon ratio could influence the degree of O-O breaking and enhance ·OH generation. Finally, the BFD electrode's operating parameters were perfected, and the COD removal and decolorization could reach 75.7% and 95.8% within 60 min, respectively. Fe-C composite electrodes reduce energy consumption compared with the traditional Fe/Al electrode and have a lower production cost, which provides a potential way to recycle and reuse the resources of solid waste in steelworks, the concept of "waste controlled by waste" is realized.

Impact of silver-doped alumina nanocomposite on water decontamination by remodeling of biogenic waste

The main cause of various fatal diseases in humans and animals is environmental pollution. Ag-doped alumina nanocomposite was prepared using coffee husk extract with a large BET surface area of 126.58 m² g^-1 and investigated for its antibacterial potential against both bacterial strains Escherichia coli and Salmonella typhimurium, and observed as an effective sorbent for removing the water pollution dye indigo carmine (IGC). The lowest concentration of the nanocomposite and the maximum contact time required to achieve complete inhibition of bacteria present in the contaminated water, as well as the capacity of sorption of IGC, were investigated. The results showed that the minimum inhibitory concentration of the Ag-doped alumina nanocomposite was 12 µg mL^-1 for both bacterial strains, with the highest inhibition occurring in E. coli. Moreover, the nanocomposite exhibited an experimental qt of 462.7 mg g^-1 from 160 mg L^-1 IGC solution at 50 °C and followed the Langmuir model. The thermodynamic results showed that the process was endothermic, spontaneous, and physisorptive. The nanocomposite was used to fully treat water samples contaminated with 10 mg L^-1 concentrations of IGC. For six consecutive cycles, the reuse research showed an average efficiency of 95.72 ± 3.6%. Consequently, the synthesized Ag-doped alumina nanocomposite is suitable for treatments of contaminated water.

Challenges and Future Roadmaps in Heterogeneous Electro-Fenton Process for Wastewater Treatment

The efficiency of heterogeneous electro-Fenton technology on the degradation of recalcitrant organic pollutants in wastewater is glaringly obvious. This green technology can be effectively harnessed for addressing ever-increasing water-related challenges. Due to its outstanding performance, eco-friendliness, easy automation, and operability over a wide range of pH, it has garnered significant attention from different wastewater treatment research communities. This review paper briefly discusses the principal mechanism of the electro-Fenton process, the crucial properties of a highly efficient heterogeneous catalyst, the heterogeneous electro-Fenton system enabled with Fe-functionalized cathodic materials, and its essential operating parameters. Moreover, the authors comprehensively explored the major challenges that prevent the commercialization of the electro-Fenton process and propose future research pathways to countervail those disconcerting challenges. Synthesizing heterogeneous catalysts by application of advanced materials for maximizing their reusability and stability, the full realization of H₂O₂ activation mechanism, conduction of life-cycle assessment to explore environmental footprints and potential adverse effects of side-products, scale-up from lab-scale to industrial scale, and better reactor design, fabrication of electrodes with state-of-the-art technologies, using the electro-Fenton process for treatment of biological contaminants, application of different effective cells in the electro-Fenton process, hybridization of the electro-Fenton with other wastewater treatments technologies and full-scale analysis of economic costs are key recommendations which deserve considerable scholarly attention. Finally, it concludes that by implementing all the abovementioned gaps, the commercialization of electro-Fenton technology would be a realistic goal.

Investigation of grafting silane coupling agents on superhydrophobicity of carbonyl iron/SiO2 particles for efficient oil/water mixture and emulsion separation

The present study demonstrated the wettability properties of grafting silane coupling agents on carbonyl iron (CI)/SiO₂ particles for efficient oil/water mixture and emulsion separation. CI particles were first reacted with Tetraethoxysilane (TEOS) to create a magnetic component. Then, CI/SiO₂ particles were altered by 1H,1H,2H,2H-perfluorodecyltriethoxysilane (FAS) and Hexamethyldisilazane (HDMS) to create magnetic superhydrophobic/superoleophilic, recyclable, and reusable sorbent powders. The water contact angle (WCA) values of the as-prepared particles, CI, CI/SiO₂, CI/SiO₂@FAS, and CI/SiO₂@HMDS, were 5.4° ± 1.3°, 6.4° ± 1.4°, 151.9° ± 2.1°, and 170.1° ± 1.1°, respectively. In addition, the oil contact angles (OCAs) of a variety of oils were found to be equivalent to 0°. Hence, superhydrophobic/superoleophilic particles for kind of different oils were shown sorption capacities of 1.7-3.1 g/g and 2.5-4.3 g/g for CI/SiO₂@FAS, and CI/SiO₂@HMDS, respectively. Besides, for 1%w/w hexane/water emulsion separation efficiency higher than 99%, the lowest mass was obtained at 50 and 200 mg for CI/SiO₂@HDMS and CI/SiO₂@HDMS, respectively, suggesting a new effective material for separating tiny oil droplets. Also, the reusability and chemical durability of the superhydrophobic samples made them a prime candidate for use in different harsh conditions.

Photovoltaic-driven electrochemical remediation of drilling fluid wastewater with simultaneous hydrogen production

In this work, we studied the application of photovoltaic solar energy for driving the electrochemical processes of electrocoagulation and electrooxidation to remediate drilling fluid wastewater, and simultaneously harvest energy in the form of electrolytic hydrogen gas produced at the cathode. The electrocoagulation was performed with sacrificial aluminium electrodes and electrooxidation with dimensionally stable boron-doped diamond electrodes in batch-wise and continuously operated mode, and their efficiency in both pollutants removal and hydrogen gas production was elucidated. The parameters affecting the efficiency of the applied electrochemical processes, such as applied current density, pH, electroprocessing time and flow rate, were investigated. The electrochemical processing was monitored by measuring the chemical oxygen demand (COD) of treated wastewater. The electrocoagulation treatment conducted with current densities of 30, 60 and 90 mA/cm² reduced the wastewater COD by about 67%, whereas the electrooxidation treatment at the same conditions yielded a COD removal of over 95%. The amount of produced hydrogen was 171 L/g COD removed from treated wastewater.

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.

New hybrid strategy of the photo-Fered-Fenton process assisted by O3 for the degradation of wastewater from the pretreatment of biodiesel production

The present work aims to fill a scientific gap regarding the treatment of wastewater from the enzymatic pretreatment of biodiesel production (WEPBP), as well as the identification of organic contaminants present in this complex matrix. Different treatment strategies were proposed for the removal of total organic carbon (TOC) and chemical oxygen demand (COD) from WEPBP. The interesting combination of O₃/H₂O₂/UV-Vis and electrocoagulation (EC) process was studied in two setups, with the EC process applied prior to O₃/H₂O₂/UV-Vis and vice versa. Further, the innovative hybrid system based on the photo-Fered-Fenton process with O₃ addition (PEF-Fere-O₃) was preliminarily studied for WEPBP treatment. The hybrid system provided the best results for the WEPBP treatment when the reactor was operated at pH of 4.5, 65 mg O₃ L^-1 and 10000 mg H₂O₂ L^-1, UV-Vis was used as the irradiation source, and the current intensity of 3.0 A. Removals of 45% of TOC and 68.7% of COD were reached within 45 min. Oleic acid, linoleic acid, and Diisooctyl phthalate (DIOP) were the main organic contaminants identified in the WEPBP as determined by Gas Chromatography-Mass Spectrometry (GC-MS) analysis. Acute toxicity assays with the bio indicator Artemia salina were carried out in untreated and treated WEPBP samples, indicating that the PEF-Fere-O₃ treatment decreased the amount of contaminants present in the WEPBP as well as reduced the toxicity levels and increased biodegradability index, suggesting its great potential for the treatment of complex industrial wastewaters.

Simultaneous removal of fluoride and nitrate from synthetic aqueous solution and groundwater by the electrochemical process using non-coated and coated anode electrodes: A human health risk study

Co-presence of fluoride (F^-) and nitrate (NO₃^-) in water causes numerous health complications. Thus, they should be eliminated by an appropriate method like the EC process. In this research, simultaneous removal of F^- and NO₃^- from synthetic aqueous solution and groundwater has been considered by the EC technique under operational parameters like anode materials (un-coated (Al and Fe) and synthesized coated (Ti/TiRuSnO₂ and Ti/PbO₂)), cathode materials (Cu, St, and Gr), current density (12, 24, and 36 mA/cm²), inter-electrode distance (0.5, 1, and 2 cm), pH (5.5, 7, and 8.5), NaCl concentrations (0.5, 1, and 1.5 g/L), electrolysis time (15, 30, 45, 60, 90, and 120 min), NO₃^- concentrations (75, 150, and 225 mg/L), and F^- concentrations (2, 4, 6, and 8 mg/L) for the first time in this research. The results proved that Al as non-coated anode and Cu as cathode electrodes were more effective in the co-removal of F^- and NO₃^-. The maximum removal efficiencies of 94.19 and 95% were observed at the current density of 36 mA/cm², 1 cm of inter-electrode distance, pH 7, 1 g/L of NaCl, and 90 min electrolysis time by Al-Cu electrode for F^- (2 mg/L) and NO₃^- (75 mg/L), respectively. The higher efficiency of Al-Cu electrodes was due to the simultaneous occurrence of electrocoagulation, electroreduction, and electrooxidation processes. Al-Cu electrode application considerably diminished f- and NO3- concentrations in the groundwater. Health risk assessment proved that HQ of F^- was significantly decreased after treatment by the Al-Cu electrode. Thus, the EC process using an appropriate and effective electrode is a promising technique for treating aqueous solutions containing F^- and NO₃^-.

Investigation of Dioctyl Sodium Sulfosuccinate in Demulsifying Crude Oil-in-Water Emulsions

This research investigated the performance of dioctyl sodium sulfosuccinate (DSS), a double-chain anionic surfactant, in breaking crude oil-in-water emulsions. The response surface methodology was used to consider the effect of the DSS concentration, oil concentration, and shaking time on demulsification efficiency and obtain optimum demulsification conditions. Further single-factor experiments were conducted to investigate the effects of salinity, crude oil conditions (fresh and weathered), and gravity separation settling time. The results showed that DSS efficiently demulsified stable emulsions under different oil concentrations (500-3000 mg/L) within 15 min shaking time. Increasing DSS concentration to 900 mg/L (critical micelle concentration) increased the demulsification efficiency to 99%. DSS not only improved the demulsification efficiency but also did not impede the demulsifier interfacial adsorption at the oil-water interface due to the presence of the double-chain structure. The low molecular weight enables the homogeneous distribution of DSS molecules in the emulsion, leading to a high demulsification efficiency within 15 min. Analysis of variance results indicated the importance of considering the interaction of oil concentration and shaking time in demulsification. DSS could reduce the total extractable petroleum hydrocarbons in the separated water to <10 mg/L without gravity separation and could achieve promising demulsification performance at high salinity (36 g/L) and various concentrations of fresh and weathered oil. The demulsification mechanism was explained by analyzing the microscopic images and the transmittance of the emulsion. DSS could be an efficient double-chain anionic surfactant in demulsifying stable oil-in-water emulsions.

Electrocoagulation and electrooxidation technologies for pesticide removal from water or wastewater: A review

Pesticides are known to be threats to the environment and human health. Excessive use of pesticides in agricultural practice can contaminate water bodies, leading to cancer, asthma, neurological disorders, reproductive defects, and hormonal disruption. Electrochemical methods such as electrocoagulation and electrooxidation can be used for pesticide removal due to their numerous advantages such as high efficiency, less sludge production, and low operational cost. During electrocoagulation, dissolution of anode metals results in metal hydroxide complexes, which precipitate with the contaminant present in the reactor. Simultaneously, electro-flotation occurs at the cathode and results in the evolution of hydrogen gas bubbles, leading to flotation of floc to the top surface of the reactor. This review focuses on the removal mechanisms, kinetics, modeling, effects of influencing factors, and sludge characterization of pesticide removal using electrocoagulation and electrooxidation. Major influencing factors include cell configuration, electrode material, current density, pH, supporting electrolyte concentration. In general, aluminum and iron are the most common electrodes used for pesticide removal using electrocoagulation, while boron-doped diamond was used to a far greater extent as the electrode in electrooxidation studies. Greater than 99% removal efficiency was observed in both processes. Overall, this review summarizes the use of electrochemical methods for pesticide removal and offers valuable information to researchers in this area of study.

Adsorption of rutin from olive mill wastewater using copolymeric hydrogels based on N-vinylimidazole: Kinetic, equilibrium, and thermodynamics assessments

Olive mill wastewater, also known as olive wastewater, contains biologically active components with various beneficial effects on health. The development of novel adsorbent materials for the recovery of these biologically active substances is important area of research. In this study, copolymeric hydrogels based on N-vinylimidazole (VIm), a new material that has never been used as an adsorbent in the separation of phenolic components, were synthesized. The hydrogels synthesized in this study is copolymer structures based on N-vinylimidazole (VIm) containing [2- (methacryloxy) ethyl] dimethylpentylammonium bromide (QDMAC5) in different moles. QDMAC5 was obtained by quaternization of 2- (dimethylamino) ethyl methacrylate (DMA) with 1-bromopentane (C5). The production of copolymer hydrogels was carried out by free radical solution polymerization. The syntheses were carried out only by changing the monomer composition so that the crosslinker ratio remained constant (1.2 mol%). The QDMAC5 content in the copolymers was 5, 10, 20, 30, and 50 mol%. So, the resulting structures were named PVQ-5%, PVQ-10%, PVQ-20%, PVQ-30%, and PVQ-50%, respectively. Functional group characterizations of hydrogels were made by Fourier Transform Infrared Spectrometry (FTIR). The surface of the hydrogels was analyzed by Scanning Electron Microscopy (SEM). Finally, thermogravimetric analyzes (TGA) were performed to investigate the thermal degradation behavior. The recovery of the rutin present in olive mill wastewater has been investigated as a model study. Kinetic data has been represented by the selected models (pseudo-first order, pseudo-second order, and intraparticle diffusion) convincingly (R² > 0.76), while the equilibrium findings have fitted well to Langmuir, Freundlich, and Temkin equations (R² > 0.77). Rutin adsorption process on N-vinylimidazole (VIm) based copolymeric hydrogels has been found as exothermic and spontaneous chemisorption process depending on the thermodynamic analysis.

Effect of additional Fe2+ salt on electrocoagulation process for the degradation of methyl orange dye: An optimization and kinetic study

The wastewater generated from textile industries is highly colored and contains dyes including azo dyes, which are toxic to human and water-living organisms. The treatment of these azo dyes using conventional treatment techniques is challenging due to their recalcitrant properties. In the current study, the effect of additional Fe²⁺ on electrocoagulation (EC) using Fe electrodes has been studied for the removal of methyl orange (MO) azo dye. pH between 4-5 was found to be optimum for EC and treatment efficiency decreased with increasing dye concentrations. With the addition of Fe²⁺ salt, dye removal for a certain concentration was increased with the increase of current density and Fe²⁺ up to a certain limit and after that, the removal efficiency decreased. The COD, color and dye removals were 88.5%, 93.1% and 100%, respectively, for EC of 200 mg.L⁻¹ dye solution using only 0.20 mmol.L⁻¹ Fe²⁺ for 0.40 mA cm⁻² current density, whereas for EC, the respective removal efficiencies were 76.7%, 63.4% and 82.4% for 32 min. The respective operating cost for EC was $768 kg⁻¹ removed dye ($0.342 m⁻³), whereas, for EC with additional Fe²⁺ salt, it was $350 kg⁻¹ removed dye ($0.189 m⁻³). The kinetic results revealed that the first-order kinetic model was fitted best for EC, whereas the second-order kinetic model was best fitted for Fe²⁺ added EC. For real textile wastewater, 57.6% COD removal was obtained for 0.15 mmol.L⁻¹ Fe²⁺ added EC compared to 27.8% COD removal for EC for 32 min. Based on the study we can conclude that Fe²⁺ assisted EC can be used for effective treatment of textile wastewater containing toxic compounds like azo dyes.

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EC represents limiting treatment performance for higher contaminant concentrations.

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0.20 mmol.L⁻¹ Fe²⁺ salt enhances the EC treatment performance of MO dye to 100%.

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EC followed first-order kinetic model, whereas Fe²⁺ added EC followed second-order kinetic model.

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Operating cost was reduced to $0.327 m⁻³ from $0.598 m⁻³ for EC with additional Fe²⁺.

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58% COD was removed for 0.15 mmol.L⁻¹ Fe²⁺ added EC for real textile wastewater.