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

Biochemical responses and phytoremediation potential of Azolla imbricata (Roxb.) Nakai in water and nutrient media exposed to waste metal cutting fluid along with temperature and humidity stress

Phytoremediation of metals from water (WM) and nutrient (NM) media exposed to waste metal cutting fluid (WMCF) along with temperature (T) and humidity (H) stress was tested using Azolla imbricata (Roxb.) Nakai. In the absence of WMCF, biomass was higher in NM than in WM during all tests. Surprisingly, opposite results were noted in the presence of WMCF, with growth failing at exposure to > 0.1% and > 0.5% in NM and WM, respectively. Further, correlation analysis of the growth data following WM exposure revealed that biomass was affected positively by T and negatively by H and metal accumulation. Simultaneously, metal accumulation was affected negatively by T and positively by H. The average accumulations of Al, Cd, Cr, Fe, Pb, and Zn across all T/H tests were 540, 282, 71, 1645, 2494 and 1110 mg·kg^-1, respectively. The observed bioconcentration factor indicated that A. imbricata acts as a hyperaccumulator or accumulator of Zn (>10) and as either accumulator (>1) or excluder (<1) of the other metals. Overall, the phytoremediation performance of A. imbricata in multi-metal-contaminated WMCF was high in WM under all environmental conditions. Therefore, the use of WM is an economically feasible approach for the removal of metals from WMCF.

Electrocoagulation of Corrugated Box Industrial Effluents and Optimization by Response Surface Methodology

The electrocoagulation method using stainless steel anodes was applied to a corrugated cardboard box manufacturing plant's wastewater with high COD content. The effects of current density, processing time and stirring speed on response functions were studied using the Response Surface Methodology (RSM). The removal efficiency of chemical oxygen demand (COD) and energy consumption were selected as response functions. The Central Composite Design (CCD) was chosen to explain the single and combined effects of independent variables on response functions. The COD concentration of the real industrial wastewater used in the experiments was 9130 mg L^-1. The maximum COD removal efficiency of 91.6% is obtained with 19.78 Wh g^-1 energy consumption. Current density and treatment time were effective parameters for both COD removal and energy consumption. Optimization for maximum COD removal with minimum energy consumption showed 80.9% of COD removal with 6.7 Wh g^-1 of energy consumption at 15 mA cm^-2, 700 rpm, and 28 min treatment time. The variables are optimized with a few experiments using the response surface method.

Graphical abstract

Circulating purification of cutting fluid: an overview

Cutting fluid has cooling and lubricating properties and is an important part of the field of metal machining. Owing to harmful additives, base oils with poor biodegradability, defects in processing methods, and unreasonable emissions of waste cutting fluids, cutting fluids have serious pollution problems, which pose challenges to global carbon emissions laws and regulations. However, the current research on cutting fluid and its circulating purification technique lacks systematic review papers to provide scientific technical guidance for actual production. In this study, the key scientific issues in the research achievements of eco-friendly cutting fluid and waste fluid treatment are clarified. First, the preparation and mechanism of organic additives are summarized, and the influence of the physical and chemical properties of vegetable base oils on lubricating properties is analyzed. Then, the process characteristics of cutting fluid reduction supply methods are systematically evaluated. Second, the treatment of oil mist and miscellaneous oil, the removal mechanism and approach of microorganisms, and the design principles of integrated recycling equipment are outlined. The conclusion is concluded that the synergistic effect of organic additives, biodegradable vegetable base oils and recycling purification effectively reduces the environmental pollution of cutting fluids. Finally, in view of the limitations of the cutting fluid and its circulating purification technique, the prospects of amino acid additive development, self-adapting jet parameter supply system, matching mechanism between processing conditions and cutting fluid are put forward, which provides the basis and support for the engineering application and development of cutting fluid and its circulating purification.

Model-based strategy for nitrogen removal enhancement in full-scale wastewater treatment plants by GPS-X integrated with response surface methodology

Model simulation is an effective approach to optimize the operational performance of wastewater treatment plants (WWTPs). This study presents a novel strategy to enhance the total nitrogen (TN) removal in WWTPs by GPS-X integrated with response surface methodology. The sensitivities of 61 parameters were screened and analyzed, and 6 critical parameters (i.e., μ_{max A}, K_A/a, μ_{max H}, K_H/ss, Y_H and μ_maxPAO) were selected for further adjustment. The accuracy of GPS-X for WWTPs modeling was validated by static and dynamic simulations with actual operational data. The results showed that the DO concentration diffused in different biological compartments exhibited significant effects on the denitrification rate. The TN removal is also associated with SRT. The significance and optimization orders of key parameters were analyzed. With the optimization of DO in biological units and SRT, the nitrification and denitrification rates were improved to 97.1 and 85.3% respectively, saving 17.9% energy consumption.

Pollutants removals and energy consumption in electrochemical cell for pulping processes wastewater treatment: Artificial neural network, response surface methodology and kinetic studies

Response surface methodology (RSM) and artificial neural network (ANN) were used for modelling the electrocoagulation removal of pollutants from wastewater from pulping processes. The Design of Experiment based on central composite design was used to investigate the combine effects of pH (5.4-9.0), time (10-45 min) and current density (j) (9-39 mA/m²), on the removal efficiency of the Chemical Oxygen Demand (COD), Total Dissolve Solids (TDS) as well as Turbidity while Energy consumption (EC) was estimated per kg [COD] removed. The kinetics of the process was modelled with pseudo first and second order models. The removability of the COD, TDS and Turbidity were found to be 76.4, 57.0 and 97.13% with Energy consumption of 2.72 kWh/kg_[COD] at optimal pH 6.83, current density of 22.06 mA/m², and reaction time of 45 min. The ANN model gave a better fitting of the electrocoagulation process than the RSM, considering the R² of 0.999 and MSE of 0.00753 obtained for the former. The pseudo first order model gave a better analysis of the kinetic data. The characterization of the sludge produced showed the potential of its use as adsorbent for organic or mineral contaminants and recovery of aluminium and other metals. Thus, electrocoagulation with monopolar aluminium electrodes displayed effective and a viable alternative for the pollutants removal from pulp processing wastewater.

Performance Evaluation and Optimization of Dyes Removal using Rice Bran-Based Magnetic Composite Adsorbent

Although several studies have explored green adsorbent synthesized from many types of agriculture waste, this study represents the first attempt to prepare an environmentally friendly rice bran/SnO₂/Fe₃O₄-based absorbent with economic viability and material reusability, for the promotion of sustainable development. Here, rice bran/SnO₂/Fe₃O₄ composites were successfully synthesized and applied for adsorption of reactive blue 4 (RB4) and crystal violet (CV) dyes in aqueous solutions. The adsorption data were well-fitted by the Langmuir isotherm model and the pseudo-second-order kinetic model. The maximum adsorption capacities of the RB4 and CV dyes as indicated by the Langmuir isotherm model were 218.82 and 159.24 mg/g, respectively. As results of response surface methodology (RSM) showed, the quadratic model was appropriate to predict the performance of RB4 dye removal. The findings exhibited that an optimum removal rate of 98% was achieved at 60 °C for pH 2.93 and adsorption time of 360 min. Comparative evaluation of different agricultural wastes indicated that the rice bran/SnO₂/Fe₃O₄ composite appeared to be a highly promising material in terms of regeneration and reusability, and showed that the composite is a potential adsorbent for dye removal from aqueous solutions. Overall, the study results clearly suggest that an adsorbent synthesized from rice bran/SnO₂/Fe₃O₄ magnetic particle composites provides encouraging adsorption capacity for practical applications for environmental prevention.

Modeling and optimizing electro-persulfate processes using Fe and Al electrodes for paper industry wastewater treatment

In this study, the treatment of paper industry wastewaters by the electrocoagulation (EC) process with a strong oxidant, persulfate addition, was investigated. Persulfate was activated by dissolution of Fe and Al from electrodes during the process. Central composite design method, being one of the response surface methods, was applied for the optimization of process parameters and the development of a mathematical model for chemical oxygen demand (COD) removal from paper industry wastewaters. The effects of S₂O₈ ^-2/COD ratio, current, pH, and reaction time, being the variables of process, were assessed on the efficiency of contaminant removal. For COD removal in EC processes in which Fe and Al electrodes were used, the model's correlation coefficients (R²) were determined as 90.14% and 87.46%, respectively. As the result of experimental study actualized under optimum conditions determined by the model in order to obtain maximum contaminant removal, COD removal efficiencies were determined as 63.5% and 72.8% respectively for the Fe electrode (S₂O₈ ^-2/COD ratio: 1.25, current: 4.14 A, pH: 6, and reaction time: 5 minutes), and the Al electrode (S₂O₈ ^-2/COD ratio: 0.5, current: 4.25 A, pH: 7.25, and reaction time: 25 minutes). Electro-activated persulfate process is an appropriate treatment alternative for COD removal from paper industry wastewaters.

Hydrochloric Acid Leaching Study of Rare Earth Elements from Moroccan Phosphate

As part of the valorization of the Moroccan phosphate rock by extraction of rare earths, different experiments on natural Moroccan phosphate from the Gantour Basin (basin of phosphate in the Youssoufia area) were done in the REMATOP laboratory. The response surface methodology was used to study the effects of the influence of different parameters (acid concentration, solid/liquid ratio, duration of the reaction, stirring speed, and temperature) on the progress of the phosphate rock’s dissolution process to determine the optimal parameters for the extraction of rare earths. The analyses were made at the same time on the mineral matrix and the solutions resulting from the attack of this matrix by different concentrations of hydrochloric acid. The rare earth analyses done by the ICP-MS technique have shown an overall amount of rare earths (ΣREs) of 228.408 ppm with the existence of yttrium as the major element.

Optimizing electrocoagulation process using experimental design for COD removal from unsanitary landfill leachate

Leachate is the most difficult wastewater to be treated due to its complex content and high pollution release. For this reason, since it is not possible to be treated with a single process, a pre-treatment is needed. In the present study, a batch electrocoagulation reactor containing aluminum and iron electrodes was used to reduce chemical oxygen demand (COD) from landfill leachate (Tunceli, Turkey). Optimization of COD elimination was carried out with response surface methodology to describe the interaction effect of four main process independent parameters (current density, inter-electrode distance, pH and time of electrolysis). The optimum current density, inter-electrode distance, pH and time of electrolysis for maximum COD removal (43%) were found to be 19.42 mA/m², 0.96 cm, 7.23 and 67.64 min, respectively. The results shown that the electrocoagulation process can be used as a pre-treatment step for leachate.

Optimization of paper mill industry wastewater treatment by electrocoagulation and electro-Fenton processes using response surface methodology

This study deals with chemical oxygen demand (COD), phenol and Ca⁺² removal from paper mill industry wastewater by electrocoagulation (EC) and electro-Fenton (EF) processes. A response surface methodology (RSM) approach was employed to evaluate the effects and interactions of the process variables and to optimize the performance of both processes. Significant quadratic polynomial models were obtained (R² = 0.959, R² = 0.993 and R² = 0.969 for COD, phenol and Ca⁺² removal, respectively, for EC and R² = 0.936, R² = 0.934 and R² = 0.890 for COD, phenol and Ca⁺² removal, respectively). Numerical optimization based on desirability function was employed; in a 27.55 min trial, 34.7% of COD removal was achieved at pH 9 and current density 96 mA/cm² for EC, whereas in a 30 min trial, 74.31% of COD removal was achieved at pH 2 and current density 96 mA/cm² and H₂O₂/COD molar ratio 2.0 for EF. The operating costs were calculated to be 6.44 €/m³ for EC and 7.02 €/m³ for EF depending on energy and electrode consumption at optimum conditions. The results indicate that the RSM is suitable for the design and optimization of both of the processes. However, EF process was a more effective technology for paper mill industry wastewater treatment as compared with EC.