Electrocoagulation in a packed bed reactor-complete treatment of color and cod from real textile wastewater

Comprehensive study on the selection and performance of the best electrode pair for electrocoagulation of textile wastewater using multi-criteria decision-making methods (TOPSIS, VIKOR and PROMETHEE II)

The accelerating environmental impact of the textile industry, especially in water management, requires efficient wastewater treatment strategies. This study examines the effectiveness of various electrode pairs in the Electrocoagulation (EC) process for treating textile wastewater, focusing on removing of Total Suspended Solids (TSS), turbidity, Chemical Oxygen Demand (COD), and Total Organic Carbon (TOC). A comprehensive analysis was conducted using thirty-six electrode pair combinations, consisting of six materials: Aluminium (Al), Zinc (Zn), Carbon (C), Copper (Cu), Mild Steel (MS), and Stainless Steel (SS). The results demonstrated that different electrode pairs yielded varying removal efficiencies for various pollutants, with the highest efficiencies being 92.09% for COD (Al-C pair), 99.66% for TSS (Al-Cu pair), 99.17% for turbidity (Al-MS pair), and 70.99% for TOC (SS-SS pair). However, no single electrode pair excelled in removing all pollutant categories. To address this, three Multi-Criteria Decision Making (MCDM) methods such as TOPSIS, VIKOR, and PROMETHEE II were used to assess the most effective electrode pair. The results indicated that the Al-Zn combination was the most efficient, exhibiting high removal efficiencies for various pollutants (99.32% for TSS, 98.88% for turbidity, 68.62% for COD, and 57.96% for TOC). This study demonstrates that the EC process can effectively treat textile effluent and emphasizes the importance of selecting suitable electrode materials. Furthermore, pollutant removal was optimal with the Al-Zn electrode pair, offering a balanced and efficient approach to textile wastewater treatment. Thus, MCDM methods offer a robust framework for assessing and optimizing electrode selection, providing valuable insights for sustainable environmental management practices.

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.

A Review of Hybrid Process Development Based on Electrochemical and Advanced Oxidation Processes for the Treatment of Industrial Wastewater

Nowadays, increased human activity, industrialization, and urbanization result in the production of enormous quantities of wastewater. Generally, physicochemical and biological methods are employed to treat industrial effluent and wastewater and have demonstrated high efficacy in removing pollutants. However, some industrial effluent and wastewater contain contaminants that are extremely difficult to remove using standard physicochemical and biological processes. Previously, electrochemical and hybrid advanced oxidation processes (AOP) were considered a viable and promising alternative for achieving an adequate effluent treatment strategy in such instances. These processes rely on the production of hydroxyl radicals, which are highly reactive oxidants that efficiently break down contaminants found in wastewater and industrial effluent. This review focuses on the removal of contaminants from industrial effluents and wastewater through the integration of electrochemical and advanced oxidation techniques. These processes include electrooxidation, electrocoagulation/electroflocculation, electroflotation, photo-Fenton, ozone-photo-Fenton, sono-photo-Fenton, photo-electro-Fenton, ozone/electrocoagulation, sono-electrocoagulation, and peroxi/photo/electrocoagulation. The data acquired from over 150 published articles, most of which were laboratory experiments, demonstrated that the hybrid process is more effective in removing contaminants from industrial effluent and wastewater than standalone processes.

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.

Preparation and Characterization of Biochar Derived from Agricultural By-Products for Dye Removal

In this study, biochar was derived from the agricultural by-products coconut coir (BC1) and rice husk (BC2) activated with NaOH 25%. This material was characterized through analytical methods such as SEM images, XRD, FTIR, and Raman. Analysis results indicated that the carbon structure carbon is amorphous and with many graphene layers. A high specific surface area was detected with 364.22 m2.g-1 for BC1 and 329.71 m2.g-1 for BC2 with many meso and micropores when analyzed by N2 and CO2 adsorption. The material also showed anionic and cationic dye adsorption capacity for textile wastewater following both Langmuir and Freundlich models where BC2 had better max adsorption capacity compared to BC1, 6.519 mg.g-1 for MO and 8.612 mg.g-1 for MB.

Electrocoagulation technology for water purification: An update review on reactor design and some newly concerned pollutants removal

Water shortage and quality deterioration are plaguing people all over the world. Providing sustainable and affordable treatment solutions to these problems is a need of the hour. Electrocoagulation (EC) technology is a burgeoning alternative for effective water treatment, which offers the virtues such as compact equipment, easy operation, and low sludge production. Compared to other water purification technologies, EC shows excellent removal efficacy for a wide range of contaminants in water and has great potential for addressing limitations of conventional water purification technologies. This review summarizes the latest development of principle, characteristics, and reactor design of EC. The design of key parameters including reactor shape, power supply type, current density, as well as electrode configuration is further elaborated. In particular, typical water treatment systems powered by renewable energy (solar photovoltaic and wind turbine systems) are proposed. Further, this review provides an overview on expanded application of EC in the removal of some newly concerned pollutants in recent years, including arsenite, perfluorinated compounds, pharmaceuticals, oil, bacteria, and viruses. The removal efficiency and mechanisms of these pollutants are also discussed. Finally, future research trend and focus are further recommended. This review can bridge the large knowledge gap for the EC application that is beneficial for environmental researchers and engineers.

Spectral deconvolution associated to the Gaussian fit as a tool for the optimization of photovoltaic electrocoagulation applied in the treatment of textile dyes

The objective of this study was to investigate the color removal in a binary mixture of azo dyes from the photovoltaic electrocoagulation (EC) technique, using spectral deconvolution and the Gaussian fit for qualitative and quantitative determination of the physical color parameter. Initially, a conventional energy source was used to feed the EC reactor and the experimental design was conducted according to the Rotational Central Compound Design (RCCD). The spectral deconvolution method associated to the Gaussian fit aided in the description of the composition of the sample matrix, In the first step, through the Analysis of Variance, the RCCD and the three-dimensional surface response graphs, the optimized operating conditions were identified, which corresponded to 1320 A m^-2 with an reaction time of 16.6 min, and an expected removal of 98.40% for Scarlet Red (SR) dye and 1160 A m^-2 with a run time of 15.7 min and 97.9% removal for Turquoise Blue (TB) dye. Using the photovoltaic module as the power source of the EC reactor, a maximum removal of 97 ± 0.43% for TB dye and 98% ± 0.81 for SR was obtained. The results encourage the applicability of photovoltaic module-fed EC technology as a promising alternative for the treatment of effluents containing textile dyes, as well as the use of the spectral deconvolution method associated with the Gaussian fit, for the reliability and precision of the results.

Synergetic treatment of dye contaminated wastewater using microparticles functionalized with carbon nanotubes/titanium dioxide nanocomposites

The highly efficient treatment of azo dye contaminated wastewater from the textile industry is an important but challenging problem. Herein, polydimethylsiloxane (PDMS) microparticles, incorporating multiple-walled carbon nanotubes/titanium dioxide (MWCNTs/TiO2) nanocomposites, were successfully synthesized to treat wastewater containing Rhodamine B (RhB) dyes in a synergetic approach, by combining sorption and photocatalytic degradation. The surfactant wrapping sol-gel method was applied to synthesize MWCNTs/TiO2 nanocomposites with TiO2 nanoparticles evenly distributed on the surface of the MWCNTs. The PDMS microparticles were fabricated with an oil-in-water (O/W) single emulsion template, using needle-based microfluidic devices. MWCNTs/TiO2 nanocomposites (at a weight ratio of 1%, and 2%, respectively) were mixed with the PDMS precursor as the dispersed phase, and an aqueous solution of polyvinyl alcohol (PVA) was used as the continuous phase. Highly monodispersed microparticles, with average diameters of 692.7 μm (Coefficient of Variation, CV = 0.74%) and 678.3 μm (CV = 1.04%), were formed at an applied flow rate of the dispersed and continuous phase of 30 and 200 μL min-1, respectively. The fabricated hybrid microparticles were employed for the treatment of RhB, involving a dark equilibrium for 5 hours and UV irradiation for 3 hours. The experimental conditions of applied PDMS type, mass loading amount, treatment duration, photodegradation kinetics, initial concentration of pollutants and environmental pH values were investigated in this work. The PDMS microparticles with 2 wt% MWCNTs/TiO2 nanocomposites can exhibit a removal efficiency of 85%. Remarkably, an efficiency of 70% can be retained after the microparticles have been recycled and reused for 3 cycles. The PDMS-MWCNTs/TiO2 microparticles possess a superior performance over conventional treatment approaches for dye contaminated wastewater, especially in recyclability and the prevention of secondary pollution. This work provides a feasible and eco-friendly route for developing an efficient and low-cost microfluidic method for treating complicated water environmental systems.

Treatment of re-refining effluent from lubricating oils by combining electrocoagulation and coagulation-flocculation processes

A combination of electrocoagulation and coagulation-flocculation processes was used for re-refining effluent from lubricating oils. The efficiency of the process was evaluated based on the chemical oxygen demand (COD), color, and turbidity of the refined effluent. Electrocoagulation (EC) and coagulation-flocculation parameters, such as the initial pH (3.00, 4.41, and 9.00), and current density (4, 9, and 16 A/m²), and the use of aluminum polychloride coagulant and superfloc A300 flocculant were studied. EC performed at pH 9, with a current density of 16 A/m² and 7 V, resulted in removal efficiencies of 85.14%, 99.81%, and 99.85%, for COD, color, and turbidity, respectively. The removal efficiencies increased to 96%, 99.87%, and 99.94% for COD, color, and turbidity, respectively, by the further coagulation-flocculation treatment in the presence of 13.8 mg/L aluminum polychloride coagulant and 80 mg/L Superfloc A300 flocculant.

Membrane bioreactors and electrochemical processes for treatment of wastewaters containing heavy metal ions, organics, micropollutants and dyes: Recent developments

Research and development activities on standalone systems of membrane bioreactors and electrochemical reactors for wastewater treatment have been intensified recently. However, several challenges are still being faced during the operation of these reactors. The current challenges associated with the operation of standalone MBR and electrochemical reactors include: membrane fouling in MBR, set-backs from operational errors and conditions, energy consumption in electrochemical systems, high cost requirement, and the need for simplified models. The advantage of this review is to present the most critical challenges and opportunities. These challenges have necessitated the design of MBR derivatives such as anaerobic MBR (AnMBR), osmotic MBR (OMBR), biofilm MBR (BF-MBR), membrane aerated biofilm reactor (MABR), and magnetically-enhanced systems. Likewise, electrochemical reactors with different configurations such as parallel, cylindrical, rotating impeller-electrode, packed bed, and moving particle configurations have emerged. One of the most effective approaches towards reducing energy consumption and membrane fouling rate is the integration of MBR with low-voltage electrochemical processes in an electrically-enhanced membrane bioreactor (eMBR). Meanwhile, research on eMBR modeling and sludge reuse is limited. Future trends should focus on novel/fresh concepts such as electrically-enhanced AnMBRs, electrically-enhanced OMBRs, and coupled systems with microbial fuel cells to further improve energy efficiency and effluent quality.

Modeling adsorption kinetic of crystal violet removal by electrocoagulation technique using bipolar iron electrodes

This paper studies the removal of crystal violet (CV) dye by electrocoagulation (EC) process using bipolar iron electrodes. Numerous operating parameters such as initial CV solution concentration, speed of agitation, number of electrodes, type and quantity of supporting electrolyte, temperature- and initial pH were investigated. A complete removal of 10 mg/L CV was achieved within 10 min at pH 7, 0.5 g NaCl, 1 LCV, 750 rpm, 9 sheets, 17.36 mAcm², and 25 °C. The performed energy-dispersive X-ray spectroscopy (EDAX), scanning electron microscopy (SEM) and Fourier transform infrared spectroscopy (FTIR) analyses confirmed the adsorption of CV onto the insoluble iron hydroxide flocs. Amongst the studied adsorption isotherms models, Langmuir and Dubinin-Radushkevich were the most applicable. The kinetic of adsorption of CV onto flocs during the EC operation was studied using the pseudo-first-order, pseudo-second-order, and intraparticulate diffusion models, with results affirming that the adsorption process proceeded according to the pseudo-second-order model. The study of thermodynamic parameters (ΔG⁰, ΔH⁰, and ΔS⁰,) of the CV removal at different temperatures reflected the feasibility of the spontaneous randomness of endothermic adsorption, especially at lower temperatures. The multiple regression equation of the removal of CV by EC technique under the different studied conditions was predicted.

Combined electrocoagulation and electro-oxidation of industrial textile wastewater treatment in a continuous multi-stage reactor

A combined electrocoagulation (EC) and electrochemical oxidation (EO) industrial textile wastewater treatment potential is evaluated in this work. A fractional factorial design of experiment showed that EC current density, followed by pH, were the most significant factors. Conductivity and number of electrooxidation cells did not affect chemical oxygen demand degradation (DCOD). Aluminum and iron anodes performed similarly as sacrificial anodes. Current density, pH and conductivity were chosen for a Box-Behnken design of experiment to determine optimal conditions to achieve a high DCOD minimizing operating cost (OC). The optimum to achieve a 70% DCOD with an OC of USD 1.47/m³ was: pH of 4, a conductivity of 3.7 mS/cm and a current density of 4.1 mA/cm². This study also shows the applicability of a combined EC/EO treatment process of a real complex industrial wastewater.

A review of electrocoagulation technology for the treatment of textile wastewater

The conventional coagulation technique of textile wastewater treatments is plagued with the issue of low removal rate of pollutants and generation of a large quantity of sludge. Recently, electrocoagulation (EC) technique gained immense attention due to its efficiency. The technique involves dissolution of the sacrificial anodes to provide an active metal hydroxide as a strong coagulant that destabilizes and amasses particles and then removes them by precipitation or adsorption. EC process is influenced by operating parameters such as applied current density, electrodes material and configuration, type of electrical connection, pH and conductivity of the solution, and mixing state. Consequently, this work reviewed the major and minor reactions of EC process with operational parameters, design of EC cell, mass transfer studies and modeling, and industrial wastewater applications. The work also includes comparison of EC technique with conventional coagulation and combinations with other techniques. Special emphasis is on removal of pollutants from textile wastewater. Further, the electrical energy supplies and cost analysis are also discussed. Even though several publications have covered EC process recently, no review work has treated the systematic process design and how to minimize the effect of passivation layer deposited on the surface of the electrodes. EC process with rotating electrodes has been recommended to reduce this phenomenon. The effect of electrodes geometry is considered to enhance the conductivity of the cell and reduce energy consumption. The studies of ionic mass transfer were not implemented before special by limiting current method during the EC process. Moreover, no aforementioned studies used computational fluid dynamics modeling to present the mass transfer inside the EC reactor.

Electrocoagulation-Adsorption to Remove Anionic and Cationic Dyes from Aqueous Solution by PV-Energy

The cationic dye malachite green (MG) and the anionic dye Remazol yellow (RY) were removed from aqueous solutions using electrocoagulation-adsorption processes. Batch and continuous electrocoagulation procedures were performed and compared. Carbonaceous materials obtained from industrial sewage sludge and commercial activated carbons were used to adsorb dyes from aqueous solutions in column systems with a 96–98% removal efficiency. The continuous electrocoagulation-adsorption system was more efficient for removing dyes than electrocoagulation alone. The thermodynamic parameters suggested the feasibility of the process and indicated that the adsorption was spontaneous and endothermic (ΔS=0.037 and −0.009 for MG and RY, resp.). The ΔG value further indicated that the adsorption process was spontaneous (−6.31 and −10.48; T=303 K). The kinetic electrocoagulation results and fixed-bed adsorption results were adequately described using a first-order model and a Bohart-Adams model, respectively. The adsorption capacities of the batch and column studies differed for each dye, and both adsorbent materials showed a high affinity for the cationic dye. Thus, the results presented in this work indicate that a continuous electrocoagulation-adsorption system can effectively remove this type of pollutant from water. The morphology and elements present in the sludge and adsorbents before and after dye adsorption were characterized using SEM-EDS and FT-IR.

Electrocoagulation by solar energy feed for textile wastewater treatment including mechanism and hydrogen production using a novel reactor design with a rotating anode

This paper describes the treatment of textile wastewater using a unique design of an electrocoagulation (EC) reactor with a rotating anode.

Optimization of material and energy consumption for removal of Acid Red 14 by simultaneous electrocoagulation and electroflotation

Decolorization of wastewater of industries which consume dye is an environmental priority. Electrocoagulation and electroflotation methods are appropriate for treatment of these wastewaters. This study investigates the effect of four parameters, electrical conductivity, current density, initial dye concentration, and initial pH, on the performance of a simultaneous electrocoagulation/electroflotation system for removal of Acid Red 14. The optimum values of these parameters were determined based on the amount of electrical energy and aluminum consumption and the best performance of coagulation and bubble generation. The optimum condition was revealed to be electrical conductivity=1,600 μS/cm, current density=60 mA/cm2, initial dye concentration=185 mg/L and initial pH=7. After less than 180 min of electrolysis, 90% dye removal was achieved with a specific energy consumption=102 kWh/kg dyeremoved, anode dissolution=2.09 kg Al/kg dyeremoved and sludge total suspended solids=15,050 mg/L. Liquid chromatography-UV-mass spectroscopy analyses were conducted on samples of raw and treated wastewater. Results showed that intermediate compounds formed from the breaking of the dye molecules. The advantages of this method are a low material and energy consumption. The amount of produced sludge was low; consequently sludge disposal and management costs would be reduced. This method should be used cautiously for treatment of textile wastewater due to the formation of intermediate compounds.

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.

Treatment of real wastewater produced from Mobil car wash station using electrocoagulation technique

This paper deals with the electrocoagulation of real wastewater produced from a car wash station using a new cell design featuring a horizontal spiral anode placed above a horizontal disc cathode. The study dealt with the chemical oxygen demand (COD) reduction and turbidity removal using electrodes in a batch mode. Various operating parameters such as current density, initial pH, NaCl concentration, temperature, and electrode material were examined to optimize the performance of the process. Also, characterization of sludge formed during electrocoagulation was carried out. The results indicated that the COD reduction and turbidity removal increase with increasing the current density and NaCl concentration; pH from 7 to 8 was found to be optimum for treating the wastewater. Temperature was found to have an insignificant effect on the process. Aluminum was superior to iron as a sacrificial electrode material in treating car wash wastewater. Energy consumption based on COD reduction ranged from 2.32 to 15.1 kWh/kg COD removed depending on the operating conditions. Finally, the sludge produced during electrocoagulation using aluminum electrodes was characterized by scanning electron microscopy (SEM) and energy dispersive spectrometry (EDS) analysis.