Study on the treatment of waste metal cutting fluids using electrocoagulation

Preparation of Multifunctional Nano-Molybdenum Disulfide and Its Tribological Properties in Water-Based Cutting Fluids

In order to meet the advanced requirements of the manufacturing industry, the use of water-based cutting fluids (WCFs) in metal processing is gradually increasing. However, their lubrication performance still needs to be improved considerably. Therefore, new multifunctional molybdenum disulfide nanoparticles (m-MoS2 NPs) were developed to improve the lubricating properties of WCFs. M-MoS2 NPs modified with silver nanoparticles were prepared by an in situ surface modification. The morphology and chemical composition of the m-MoS2 NPs were characterized by scanning electron microscopy (SEM), high-resolution transmission electron microscopy (HR-TEM), X-ray diffraction (XRD), and X-ray photoelectron spectroscopy (XPS). Furthermore, the dispersion and bactericidal properties of m-MoS2 NPs with different weight percents in WCFs were also studied experimentally. The effect of m-MoS2 NPs concentration on friction properties and their friction mechanism were investigated in this research. The results revealed that the prepared m-MoS2 NPs were all nanoscale particles with a layered structure. The dispersion and bactericidal properties of m-MoS2 NPs in WCFs were better than those of MoS2 NPs. The best dispersion and bactericidal properties were observed with 1 wt % MoS2 NPs, as well as friction reduction and antiwear properties. During friction, the two friction surfaces were in the boundary lubrication state,and the prepared m-MoS2 NPs entered the friction contact zone along with the WCFs. A friction chemical reaction film rich in MoS2 and Ag NPs was formed on the friction surface to fill and repair the worn surface, exerting a good lubrication effect.

An overview of the application of electrocoagulation for mine wastewater treatment

One of the challenges of the twenty-first century is related to the discharge and disposal of mine effluents and wastewater resulting from mine dewatering, precipitation, and surface runoff in mines, especially acidic effluents that contain a variety of toxic and heavy metals and are the main sources of surface and groundwater pollution. Various physical, chemical, and biological methods have been developed and used to treat mine effluents. All proposed methods have their own disadvantages that make their use challenging. One of the new methods used for wastewater treatment is the electrical coagulation process, which has attracted the attention of researchers in recent years due to its advantages such as simplicity, environmental friendliness, and low cost. The present review focused on the applications of electrocoagulation for mine wastewater treatment as well as metals recovery. In addition, the main mechanisms, advantages, and weaknesses of electrocoagulation were reviewed.

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.

The application of electrochemical processes in oily wastewater treatment: a review

Oily wastewater is becoming a concern worldwide due to its quantities and the presence of contaminants and its sustainable treatment should be cost-effective and meet all requirements so the contaminants are not transferred to the environment. The paper reviews the state-of-the-art in the oily wastewater treatment by electrochemical processes such as electrochemical advanced oxidation processes and electrocoagulation. Efficiency of oily wastewater treatment has been thoroughly investigated with its expression as a function of the main technological (process) parameters. Fe and Al electrodes, as well as their combination have proven to be very effective in oily wastewater treatment with slightly better performance of Al electrodes. Higher current densities and longer reaction times result with higher COD, TOC, turbidity, phenol and oil and grease removal efficiencies, but with resulting increase in wastewater temperature and energy consumption, so there is a strong need for the process optimization. There is a need for further research on the treatment efficiencies of different contaminants (heavy metals, total hydrocarbons, organic halogens, cyanides, etc.). A lack of research is presented on the treatment efficiency with electrodes of different materials as well as the analyses of the sludge production and its further treatment and use or disposal.

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.

Use of Electrocoagulation for Treatment of Pharmaceutical Compounds in Water/Wastewater: A Review Exploring Opportunities and Challenges

Increasing dependency on pharmaceutical compounds including antibiotics, analgesics, antidepressants, and other drugs has threatened the environment as well as human health. Their occurrence, transformation, and fate in the environment are causing significant concerns. Several existing treatment technologies are there with their pros and cons for the treatment of pharmaceutical wastewater (PWW). Still, electrocoagulation is considered as the modern and decisive technology for treatment. In the EC process, utilizing electricity (AC/DC) and electrodes, contaminants become coagulated with the metal hydroxide and are separated by co-precipitation. The main mechanism is charge neutralization and adsorption of contaminants on the generated flocs. The range of parameters affects the EC process and is directly related to the removal efficiency and its overall operational cost. This process only could be scaled up on the industrial level if process parameters become optimized and energy consumption is reduced. Unfortunately, the removal mechanism of particular pharmaceuticals and complex physiochemical phenomena involved in this process are not fully understood. For this reason, further research and reviews are required to fill the knowledge gap. This review discusses the use of EC for removing pharmaceuticals and focuses on removal mechanism and process parameters, the cost assessment, and the challenges involved in mitigation.

Post treatment of swine anaerobic effluent by weak electric field following intermittent vacuum assisted adjustment of N:P ratio for oil-rich filamentous microalgae production

A weak electric field (EF) was applied to decolorize the swine anaerobic effluent, which was followed by N:P ratio adjustment via intermittent-vacuum stripping (IVS) system for oil-rich filamentous microalgae Tribonema sp. cultivation. A higher electric field strength, higher temperature, and lower pH conditions showed higher efficiency in decolorization and nutrients removal during EF application. In the group of 30:1 (N:P) ratio, Tribonema sp. had the largest biomass accumulation (2.04 g·L^-1) after 14 days cultivation. However, the 20:1 group had highest oil accumulation (oil content 55.4 ± 3.4%), while 30:1 (N: P) group was 42.3 ± 1.8%. Under the conditions of sufficient nitrogen (50:1 group), the highest contents of α-linolenic acid (15.5%) and ω-3 fatty acids (21.8%) were reached. The integrated treatment of EF, IVS and microalgae cultivation demonstrated to be effective for nutrients recycling and sustainable biomass production.

Analysis of cutting-oil emulsion destabilization by aluminum sulfate

The destabilization mechanism of the high stable cutting-oil emulsion by aluminum sulfate (Al₂(SO₄)₃) was investigated since it can affect properties of aggregates and following separation units. Al₂(SO₄)₃ dosage and pH were key factors in the destabilization. The effective separation occurred when precipitated Al(OH)₃ is dominated at the neutral pH of 6.5-7.0. The best separation can be achieved when solid flocs were formed at 1.0 mM, which exceeded the dosage from the critical coagulation concentration (CCC) of 0.75 mM. Two different mechanisms were proved for the emulsion destabilization depending upon the Al³⁺ concentration under this pH range. The first mechanism was the adsorption of Al(OH)₃ on surface of oil droplets, which led to the droplet coalescence. By increasing the Al³⁺ dosage, the sweep flocculation by Al(OH)₃ precipitates occurred. Al³⁺ dosage for effective destabilization was increased in accordance with oil concentration. The formation of aluminum hydroxide precipitates in bayerite structure was affirmed by analyzing elemental composition and crystalline structure of flocs from the destablization.

Experimental analysis of chemical demulsification of cutting oil

The wastewater produced by the metal industry is often present in the form of oil-in-water (O/W) or water-in- oil (W/O) emulsions. These fluids contain a certain amount of valuable oil that can be recovered in the recycling process. Therefore, the development of novel, efficient, and low cost processes for the treatment of metalworking fluid is necessary. Demulsification to separate oil/water mixtures is a very interesting option because it allows the recovery and reuse of the lubricant oil and effects in cleaner, easily treatablemwastewater.Chemical destabilization is the most common way of demulsification of metalworking fluids. As an example, inorganic salts can be used as demulsifiers. In the presented work the efficiency of treatment of cutting emulsions with chemical demulsification with usage of aluminum sulfate (IV) is described. The emulsion was prepared with Emulgol-ES12 self-emulsyfing oil delivered by Orlen S.A. In the research the feasibility of the demulsifier was checked.The novel in this paper is determination of the optimal dosage of emulsifier using the TurbiscanLab® apparatus. It is relatively quick and precise method that can be applied in the industry.

Process optimization via response surface methodology in the treatment of metal working industry wastewater with electrocoagulation

In this study, process parameters in chemical oxygen demand (COD) and turbidity removal from metal working industry (MWI) wastewater were optimized by electrocoagulation (EC) using aluminum, iron and steel electrodes. The effects of process variables on COD and turbidity were investigated by developing a mathematical model using central composite design method, which is one of the response surface methodologies. Variance analysis was conducted to identify the interaction between process variables and model responses and the optimum conditions for the COD and turbidity removal. Second-order regression models were developed via the Statgraphics Centurion XVI.I software program to predict COD and turbidity removal efficiencies. Under the optimum conditions, removal efficiencies obtained from aluminum electrodes were found to be 76.72% for COD and 99.97% for turbidity, while the removal efficiencies obtained from iron electrodes were found to be 76.55% for COD and 99.9% for turbidity and the removal efficiencies obtained from steel electrodes were found to be 65.75% for COD and 99.25% for turbidity. Operational costs at optimum conditions were found to be 4.83, 1.91 and 2.91 €/m³ for aluminum, iron and steel electrodes, respectively. Iron electrode was found to be more suitable for MWI wastewater treatment in terms of operational cost and treatment efficiency.

Emerging usage of electrocoagulation technology for oil removal from wastewater: A review

Electrocoagulation is a simple and efficient treatment method involving the electrodissolution of sacrificial anodes and formation of hydroxo-metal products as coagulants, while the simultaneous production of hydrogen at the cathode facilitates the pollutant removal by flotation. Oil is one of the most important hydrocarbon products in the modern world. It can cause environmental pollution during various stages of production, transportation, refining and use. Electrocoagulation treatment is particularly effective for destabilization of oil-in-water emulsions by neutralizing charges and bonding oil pollutants to generated flocs and hydrogen bubbles. The development of electrocoagulation technologies provided a promising alternative for oil removal from wastewater. This paper presents a review of emerging electrochemical technologies used for treating oil-containing wastewater. It includes a brief description of the oily wastewater origin and characteristics. The treatment processes developed so far for oily wastewater and the electrocoagulation mechanisms are also introduced. This paper summarizes the current applications of electrocoagulation for oil removal from wastewater. The factors that influence the electrocoagulation treatment efficiencies as well as the process optimization and modeling studies are discussed. The state-of-the-art and development trends of electrocoagulation process for oil removal are further introduced.

Lemna minor tolerance to metal-working fluid residues: implications for rhizoremediation

For the first time in the literature, duckweed (Lemna minor) tolerance (alone or in combination with a consortium of bacteria) to spent metal-working fluid (MWF) was assessed, together with its capacity to reduce the chemical oxygen demand (COD) of this residue. In a preliminary study, L. minor response to pre-treated MWF residue (ptMWF) and vacuum-distilled MWF water (MWFw) was tested. Plants were able to grow in both residues at different COD levels tested (up to 2300 mg·l(-1) ), showing few toxicity symptoms (mainly growth inhibition). Plant response to MWFw was more regular and dose responsive than when exposed to ptMWF. Moreover, COD reduction was less significant in ptMWF. Thus, based on these preliminary results, a second study was conducted using MWFw to test the effectiveness of inoculation with a bacterial consortium isolated from a membrane bioreactor fed with the same residue. After 5 days of exposure, COD in solutions containing inoculated plants was significantly lower than in non-inoculated ones. Moreover, inoculation reduced β+γ-tocopherol levels in MWFw-exposed plants, suggesting pollutant imposed stress was reduced. We therefore conclude from that L. minor is highly tolerant to spent MWF residues and that this species can be very useful, together with the appropriate bacterial consortium, in reducing COD of this residue under local legislation limits and thus minimise its potential environmental impact. Interestingly, the lipophilic antioxidant tocopherol (especially the sum of β+γ isomers) proved to be an effective plant biomarker of pollution.

Treatment of emulsified oils by electrocoagulation: pulsed voltage applications

The effect of pulsed voltage application on energy consumption during electrocoagulation was investigated. Three voltage profiles having the same arithmetic average with respect to time were applied to the electrodes. The specific energy consumption for these profiles were evaluated and analyzed together with oil removal efficiencies. The effects of applied voltages, electrode materials, electrode configurations, and pH on oil removal efficiency were determined. Electrocoagulation experiments were performed by using synthetic and real wastewater samples. The pulsed voltages saved energy during the electrocoagulation process. In continuous operation, energy saving was as high as 48%. Aluminum electrodes used for the treatment of emulsified oils resulted in higher oil removal efficiencies in comparison with stainless steel and iron electrodes. When the electrodes gap was less than 1 cm, higher oil removal efficiencies were obtained. The highest oil removal efficiencies were 95% and 35% for the batch and continuous operating modes, respectively.

Feasibility of spent metalworking fluids as co-substrate for anaerobic co-digestion

In this paper, anaerobic co-digestion of spent metalworking fluids (SMWF) and pig manure (PM) was evaluated. Three SMWF:PM ratios were tested in order to find the highest process efficiency. The best results (COD removal efficiencies of 74%) were achieved co-digesting a mixture with a SMWF:PM ratio of 1:99, w/w(1) (corresponding to 3.75mL SMWF/Lreactor week), which indicates that SMWF did not affect negatively PM degradation. Furthermore, two different weekly SMWF pulse-frequencies were performed (one reactor received 1 pulse of 3.75mL/Lreactor and the other 3 pulses of 1.25mL/Lreactor) and no differences in COD removal efficiency were observed. Microbiology analysis confirmed that Pseudomonas was the predominant genus when treating anaerobically SMWF and the presence of a higher fraction of Archaea was indicative of good digester performance. This study confirms the feasibility of anaerobic co-digestion as an appropriate technology for treating and valorising SMWF.

Photoelectrocatalytic degradation of acid dye using Ni-TiO2 with the energy supplied by solar cell: mechanism and economical studies

This paper reports an investigation into the effect of a number of operating factors on the removal of Acid Red 88 from an aqueous solution through photoelectrocatalysis: photocatalyst dose, dye concentration, pH, bias potential, and electrolyte concentration. The photocatalyst was Ni-TiO2 applied in suspension to the solution to achieve a larger catalyst surface area. The optimum values for photocatalyst dose, dye concentration, and electrolyte concentration turned out to be 0.6 mg L(-1), 50 mg L(-1), and 5 mg L(-1), respectively. Also, the best pH was found to be 7, and bias potential proved to be best at 1.6 V. The aqueous solution was characterized for its COD and TOC. Photocatalyst efficiency was evaluated using SEM and XRD techniques. The characterization of the post-treatment product using FT-IR, HPLC, and GC-MS studies revealed intermediate compounds. A pathway was proposed for the degradation of the dye. The energy required by the experiment was supplied by solar cells, meaning the money that would have otherwise been spent on electricity was saved. Cost analysis was also done for the treatment process.

Combined phytoremediation of metal-working fluids with maize plants inoculated with different microorganisms and toxicity assessment of the phytoremediated waste

The aim of this study was to validate the effectiveness of a phytoremediation procedure for metal-working fluids (MWFs) with maize plants growing in hydroponic culture in which the roots grow on esparto fibre and further improve bioremediation potential of the system with root beneficial bacteria, seeking a synergistic effect of the plant-microorganism combination. Chemical oxygen demand (COD), pH, total and type of hydrocarbons measured after phytoremediation indicated that the process with maize plants was successful, as demonstrated by the significant decrease in the parameters measured. This effect was mainly due to the plant although inoculated microorganisms had a relevant effect on the type of remaining hydrocarbons. The success of the phytoremediation process was further confirmed by two toxicity tests, one of them based on chlorophyll fluorescence measurements on maize plants and another one based on cyanobacteria, using a bioluminescent toxicity bioassay; both tests demonstrated that the phytoremediated waste was significantly less toxic than the initial non-phytoremediated MWFs.

Treatment of colored and real industrial effluents through electrocoagulation using solar energy

This study was undertaken to investigate the removal of Acid Orange 2 (sodium 4-[(2E)-2-(2-oxonaphthalen-1-ylidene) hydrazinyl] benzenesulfonate) and Reactive Blue 19 (2-Anthracenesulfonicacid,1-amino-9,10-dihydro-9,10-dioxo-4-[[3-[[2-(sulfooxy) ethyl] sulfonyl] phenyl] amino]-,sodium salt (1:2)) from synthesized and real effluents through electrocoagulation using solar cells for the purpose of improving economic efficiency of the process. The impact of a number of key operating parameters was explored including current density, anode type, temperature, pH, and electrolyte concentration. The current density of 45 Am(-2) proved to be the optimum level for both dyes. The same optimum alternatives were found for the other parameters in both cases: iron anode, a temperature level of 25°C, a pH of 7, and an electrolyte concentration of 15 mg L(-1). Both effluent samples were subjected to COD (chemical oxygen demand) and TOC (total organic carbon) tests. Cost analysis was performed for the treatment process.

A Preliminary Study of Banana Stem Juice as a Plant-Based Coagulant for Treatment of Spent Coolant Wastewater

The effectiveness of banana stem juice as a natural coagulant for treatment of spent coolant wastewater was investigated . Three main parameters were studied, namely, chemical oxygen demand (COD), suspended solids (SSs), and turbidity of effluent. Coagulation experiments using jar test were performed with a flocculation system where the effects of spent coolant wastewater pH as well as banana stem juice dosage on coagulation effectiveness were examined. The highest recorded COD, SS, and turbidity removal percentages by banana stem juice were 80.1%, 88.6%, and 98.5%, respectively, observed for effluent at pH 7 using 90 mL dosage. The inulin concentration in the banana stem was examined to be 1.22016 mg/mL. It could be concluded that banana stem juice showed tremendous potential as a natural coagulant for water treatment purposes and could be applied in the pretreatment stage of Malaysian spent coolant wastewater prior to secondary treatment.

Assessment of a process to degrade metal working fluids using Pseudomonas stutzeri CECT 930 and indigenous microbial consortia

The development of a novel biological process to treat metal working fluids (MWFs)-containing effluents at bioreactor scale was pursued in this work. The bacteria Pseudomonas stutzeri CECT 930 was investigated for the first time as an alternative agent for MWF degradation. An adequate medium design and mixing and aeration system, as well as an appropriate microorganism proved to be crucial for reaching high levels of degradation by P. stutzeri and by an indigenous consortium (about 70% and 50% of reduction in total petroleum hydrocarbon content in less than 2 wk, respectively). Additionally, as there is no information in literature trying to kinetically characterize an MWF-polluted effluent degradation process, all the experimental data were fitted to logistic and Luedeking and Piret models, that allowed to elucidate the growth-associated character of the biodegradation process.

Treatment of pulp and paper industry bleaching effluent by electrocoagulant process

The experiments were carried out in an electrocoagulation reactor with aluminum as sacrificial electrodes. The influence of electrolysis time, current density, pH, NaCl concentration, rotational speed of the stirrer and electrode distance on reduction of color, COD and BOD were studied in detail. From the experimental results, 15 mA/cm(2) current density, pH of 7, 1 g/l NaCl, 100 rpm, 28°C temperature and 3 cm electrode distance were found to be optimum for maximum reduction of color, COD and BOD. The reduction of color, COD and BOD under the optimum condition were found to be 94%, 90% and 87% respectively. The electrode energy consumption was calculated and found to be varied from 10.1 to 12.9 kWh/m(3) depending on the operating conditions. Under optimal operating condition such as 15 mA/cm(2) current density, pH of 7, 1 g/l NaCl, 100 rpm, 28°C temperature and 3 cm electrode distance, the operating cost was found to be 1.56 US $/m(3). The experimental results proved that the electrocoagulation is a suitable method for treating bleaching plant effluents for reuse.

Treatment of cadmium and nickel electroplating rinse water by electrocoagulation

Treatments of cadmium-cyanide and nickel-cyanide electroplating rinse water were investigated in an electrochemical reactor equipped with iron plate electrodes in a batch mode by electrocoagulation (EC). Effects of the process variables such as pH, current density, and operating time were explored with respect to removal efficiencies of cadmium, nickel and cyanide in electroplating rinse water and operating costs as well. Removal efficiencies and operating costs under the optimum conditions (30 A/m2, 30 min and pH 8-10 for cadmium; 60A/m2, 80 min and pH 8-10 for nickel) for the EC process in electroplating rinse water were determined as 99.4% and 1.05/m3 for cadmium, 99.1% and 2.45/m3 for nickel and > 99.7% for cyanide, respectively. The results indicated that EC was very effective treatment for the removals of cadmium, nickel, and cyanide ions from the electroplating rinse water.

Toxicity assessment from electro-coagulation treated-textile dye wastewaters by bioassays

In this study the pollutant removal from a textile dyeing wastewater has been investigated by using the electro-coagulation technique with iron electrodes. In order to obtain optimal values of the system state variables, a 3(3) full factorial experimental design was applied. The electro-coagulation (EC) process response was evaluated on the basis of COD removal and decolourization values. The electrolysis time and density current were statistically significant for the COD removal and decolourization. Based on the lettuce seeds (Lactuca sativa) and brine shrimp (Artemia salina), the lowest toxicity level was achieved in 5 min of electrolysis time. Due to the remaining high toxicity level above 30 min of electrolysis time, the EC process is not adequate to be used in a single effluent treatment, suggesting that this electrochemical process of up to 5 min could be used as part of a complete effluent treatment system.

On the crucial influence of some supporting electrolytes during electrocoagulation in the presence of aluminum electrodes

The influence of some supporting electrolytes on aluminum electrode oxidation and pH variation during electrocoagulation of an unskimmed milk sample and a cutting oil emulsion has been investigated. Among the electrolytes studied, sulfate anions were found to be quite harmful both for electrical consumption and electrocoagulation efficiency. At the opposite, chloride and ammonium ions were particularly benefic respectively for aluminum corrosion and pH regulation, whereas sodium cations were observed to have a neutral role. The results indicate that electrocoagulation can be realized at low anodic potential even in the presence of sulfate ions when the [Cl(-)]/[SO(4)(2-)] ratio is around or greater than 1/10. The detrimental effect of sulfates on electrocoagulation efficiency can be thwarted by the use of the ammonium salt thanks to its related buffer effect.