Selection of anode materials and optimization of operating parameters for electrochemical water descaling

Turning waste into resource: Metal framework-scale composite cathode overcomes limitations of low efficiency and cathode failure in electrochemical water softening

Despite years of development, electrochemical water softening continues to face challenges in achieving high softening efficiency and maintaining long-term cathode stability. To address these issues, this study builds upon the characteristics of membrane-free electrochemical water softening and prior research by employing a large-pore stainless steel filter as the cathode. During extended operation, a fluffy, porous scale layer gradually forms on the cathode surface, transforming the stainless-steel filter into a metal framework-scale composite (MF-S) cathode. This composite cathode enhances OH⁻ enrichment and extraction, improving water softening efficiency. Additionally, the soft scale deposited on the cathode's pores and surface can be partially removed through simple backflushing, extending system's operational lifespan. Experimental results indicate that using a stainless-steel cathode with 15×10 mm pore size, the effluent pH exceeds 11.0 after 18 h of operation, with a Ca2+ hardness removal rate of over 97 %. To prevent clogging of the cathode pores during extended operation, backflushing is conducted every 25 h to remove scale. Remarkably, after 700 h of continuous operation, there is no observed decline in hardness removal efficiency, and the cathode remains functional, allowing the water softening process to continue. Electrochemical tests and finite element simulations reveal that the composite cathode significantly outperforms the stainless-steel filter cathode in generating and enriching OH⁻. The proposed composite cathode demonstrates strong practical potential, offering a new perspective for applying membrane-free, high-efficiency electrochemical water softening processes.

Ion association behaviors in the initial stage of calcium carbonate formation: An ab initio study

In this work, we performed static density functional theory calculations and ab initio metadynamics simulations to systematically investigate the association mechanisms and dynamic structures of four kinds of ion pairs that could be formed before the nucleation of CaCO3. For Ca2+-HCO3- and Ca2+-CO32- pairs, the arrangement of ligands around Ca2+ evolves between the six-coordinated octahedral structure and the seven-coordinated pentagonal bipyramidal structure. The formation of ion pairs follows an associative ligand substitution mechanism. Compared with HCO3-, CO32- exhibits a stronger affinity to Ca2+, leading to the formation of a more stable precursor phase in the prenucleation stage, which promotes the subsequent CaCO3 nucleation. In alkaline environments, excessive OH- ions decrease the coordination preference of Ca2+. In this case, the formation of Ca(OH)+-CO32- and Ca(OH)2-CO32- pairs favors the dissociative ligand substitution mechanism. The inhibiting effects of OH- ion on the CaCO3 association can be interpreted from two aspects, i.e., (1) OH- neutralizes positive charges on Ca2+, decreases the electrostatic interactions between Ca2+ and CO32-, and thus hinders the formation of the CaCO3 monomer, and (2) OH- decreases the capacity of Ca2+ for accommodating O, making it easier to separate Ca2+ and CO32- ions. Our findings on the ion association behaviors in the initial stage of CaCO3 formation not only help scientists evaluate the impact of ocean acidification on biomineralization but also provide theoretical support for the discovery and development of more effective approaches to manage undesirable scaling issues.

A novel membrane-free electrochemical separation-filtering crystallization coupling process for treating circulating cooling water

The traditional electrochemical descaling process exhibits drawbacks, including low OH- utilization efficiency, constrained cathode deposition area, and protracted homogeneous precipitation time. Consequently, this study introduces a novel membrane-free electrochemical separation-filtering crystallization (MFES-FC) coupling process to treat circulating cooling water (CCW). In the membrane-free electrochemical separation (MFES) system, OH- is rapidly extracted by pump suction from the porous cathode boundary layer solution, preventing neutralization with H+, thereby enhancing the removal of Ca2+ and Mg2+. Experimental results indicate that the pH of the pump suction water can swiftly increase from 8.13 to 11.42 within 10 min. Owing to the high supersaturation of the pump suction water, this study couples the MFES with a filtration crystallization (FC) system that employs activated carbon as the medium. This approach captures scale particles to enhance water quality and expedites the homogeneous precipitation of hardness ions, shortening the treatment time while further augmenting the removal rate. After the MFES-FC treatment, the single-pass removal rates for total hardness, Ca2+ hardness, Mg2+ hardness, and alkalinity in the effluent reached 92 %, 97 %, 64 %, and 67 %, respectively, with turbidity of 3 NTU, current efficiency of 86.6 %, and energy consumption of 7.19 kWh·kg-1 CaCO3. This coupling process facilitates an effective removal of hardness and alkalinity at a comparatively low cost, offering a new reference and inspiration for advancements in electrochemical descaling technology.

Advances on electrochemical disinfection research: Mechanisms, influencing factors and applications

Disinfection, a vital barrier against pathogenic microorganisms, is crucial in halting the spread of waterborne diseases. Electrochemical methods have been extensively researched and implemented for the inactivation of pathogenic microorganisms from water and wastewater, primarily owing to their simplicity, efficiency, and eco-friendliness. This review succinctly outlined the core mechanisms of electrochemical disinfection (ED) and systematically examined the factors influencing its efficacy, including anode materials, system conditions, and target species. Additionally, the practical application of ED in water and wastewater treatment was comprehensively reviewed. Case studies involving various scenarios such as drinking water, hospital wastewater, black water, rainwater, and ballast water provided concrete instances of the expansive utility of ED. Finally, coupling ED with other technologies and the resulting synergies were introduced as pivotal foundations for subsequent engineering advancements.

Electrochemical water softening technology: From fundamental research to practical application

In recent decades, the environmentally benign electrochemical softening process has been gaining widespread interest as an emerging alternative for water softening. But, in spite of decades of research, the fundamental advances in laboratory involving electrolytic cell design and treatment system development have not led to urgently needed improvements in industrially practicable electrochemical softening technique. In this review, we firstly provide the critical insights into the mechanism of the currently widely used cathode precipitation process and its inherent limitations, which seriously impede its wide implementation in industry. To relieve the above limitations, some cutting-edge electrochemically homogeneous crystallization systems have been developed, the effectiveness of which are also comprehensively summarized. In addition, the pros and cons between cathode precipitation and electrochemically homogeneous crystallization systems are systematically outlined in terms of performance and economic evaluation, potential application area, and electrolytic cell and system complexity. Finally, we discourse upon practical challenges impeding the industrial-scale deployment of electrochemical water softening technique and highlight the integration of strong engineering sense with fundamental research to realize industry-scale deployment. This review will inspire the researchers and engineers to break the bottlenecks in electrochemical water softening technology and harness this technology with the broadened industrial application area.

Research on the descaling characteristics of a new electrochemical water treatment device

In recent years, chemical water treatment equipment has gained significant attention due to its environmental-friendly features, multifunctionality, and broad applicability. Recognizing the limitations of existing chemical treatment equipment, such as challenges in scale removal and the high water content in scale deposits, we propose a novel drum design for both anode and cathode, enabling simultaneous scale suction and dehydration. We constructed a small experimental platform to validate the equipment's performance based on our model. Notably, under the optimal operating parameters, the hardness removal rate for circulating water falls within the range of 19.6-24.46%. Moreover, the scale accumulation rate per unit area and unit time reaches 13.7 g h-1 m-2. Additionally, the energy consumption per unit weight of the scale remains impressively low at 0.16 kWh g-1. Furthermore, the chemical oxygen demand (COD) concentration decreased from an initial 106.0 mg L-1 to a mere 18.8 mg L-1, resulting in a remarkable total removal rate of 82.26%. In conclusion, our innovative electrochemical water treatment equipment demonstrates exceptional performance in scale removal, organic matter degradation, and water resource conservation, offering valuable insights for future research and development in chemical treatment equipment and electrochemical theory.

Bibliometric analysis of electrochemical disinfection: current status and development trend from 2002 to 2022

The removal of waterborne pathogens from water is critical in preventing the spread of waterborne diseases. Electrochemical methods have been extensively researched and implemented for disinfection, primarily owing to their simplicity, efficiency, and eco-friendliness. Thus, it is essential to conduct a review about the research progress and hotspots on this promising technique. In this paper, we provided a comprehensive bibliometric analysis to systematically study and analyze the current status, hotspots, and trends in electrochemical disinfection research from 2002 to 2022. This study analyzed literature related to electrochemical disinfection or electrochemical sterilization published in the Web of Science database from 2002 to 2022 using CiteSpace and Biblioshiny R language software packages. The analysis focused on the visualization and assessment of annual publication volume, discipline and journal distribution, collaborative networks, highly cited papers, and keywords to systematically understand the current status and trends of electrochemical disinfection. The results showed that between 2002 and 2022, 1171 publications related to electrochemical disinfection were published, with an exponential increase in the cumulative number of publications (y=17.518e0.2147x, R2= 0.9788). The publications covered 76 disciplines with many articles published in high-impact journals. However, the research power was characterized by a large number of scattered research efforts and insufficient cooperation, indicating the need for further innovative collaboration. The citation analysis and keyword analysis suggest that future development in this field may focus on optimizing electrode materials, investigating the disinfection performance of ·OH based systems, optimizing conditions for actual wastewater treatment, and reducing energy consumption to promote practical applications.

Robust electrolysis system divided by bipolar electrode and non-conductive membrane for energy-efficient calcium hardness removal

In this study, an energy-efficient divided bipolar electrolysis system was developed for water softening, where two PTFE membranes were used as the separating materials and a bipolar electrode was employed to enhance the H₂O-splitting reactions. As compared with other two operation modes, the optimum calcium harness removal efficiencies of 85% and 57% could be reached in the induction cathode effluent and terminal effluent, respectively, at 8 mA cm^-2 in the mode A. Increasing the current density from 5 to 20 mA cm^-2 evidently promoted the removal of calcium hardness from 33% to 65% in the terminal effluent and the CaCO₃ precipitation rate from 743 to 1462 gCaCO₃ h^-1 m^-2 with the increased energy consumption from 0.53 to 2.2 kWh kg^-1CaCO₃. The optimized Ca²⁺/HCO₃^- molar ratio was 1:1.2 for the calcium hardness removal. In addition, increasing the flow rate into each cathode chamber from 10 to 40 mL min^-1 gradually decreased from 67% to 35%. The calcium hardness was mainly removed in the forms of vaterite and calcite in the alkaline effluents and was marginally precipitated as aragonite and calcite on the cathodes surface. Generally, present energy-efficient electrochemical water softening system showed great potential for application in industrial processes.

Spatial and temporal regulation of homogeneous nucleation and crystal growth for high-flux electrochemical water softening

Electrochemical softening is an effective technology for the treatment of circulating cooling water, but its hardness removal efficiency is limited because that nucleation and growth of scale crystals depended on cathode surface. In this study, a novel method was proposed to break through this limit via spatiotemporal management of nucleation and growth processes. A cube reactor was divided into cathodic chamber and anodic chamber via installing a sandwich structure module composed of mesh cathode, nylon nets, and mesh anode. Using this continuous-flowing electrochemical reactor, OH ̄ generated by water electrolysis was rapidly pushed away from cathode surface by water flow and hydrogen bubbles movement. As a result, a wide range of strongly alkaline regions was rapidly constructed in cathodic chamber to play a nucleation region, and homogeneous nucleation in liquid phase replaced heterogeneous nucleation on cathodic surface. Furthermore, the growth process of scale crystals in alkaline regions was monitored in situ. It took only 150 s of residence time to grow to 500 nm, which may be easily separated from water by a microfiltration membrane. With this new method, the precipitation rate was 290.8 g/(hˑm²) and corresponding energy consumption was 2.1 kW·h/kg CaCO₃, both were superior to those reported values. Therefore, this study developed an efficient electrochemical softening method by spatial and temporal regulation of homogeneous nucleation and crystal growth processes.

Constant current-exponential attenuation mode: A non-traditional power supply mode for electrocatalytic oxidation

Low average current efficiency (ACE) and high energy consumption (EC) have seriously hindered the industrial development of electrocatalytic oxidation (ECO) technology. Timely adjustment of the current output according to the attenuation law of the organic pollutants concentration during the reaction process can help to solve the low electrical energy utilization problem at source. In this study, a non-traditional power supply mode with "constant current-exponential attenuation" (Mode CC-EA) was proposed and applied to intermittent ECO systems. The current is first output in a constant state and then attenuated exponentially according to the decreasing law of pollutants concentration, enabling efficient use of electrons at all stages of the reaction, resulting in increased degradation rates and ACE, and reduced EC. Acidic red G (ARG) was used as the target pollutant and the degradation effects of the traditional constant current mode (Mode CC), the direct exponential attenuation mode (Mode EA) and the Mode CC-EA were compared with different evaluation parameters. The results showed that the optimized Mode EA (n₄) and Mode CC-EA (70-n₁₁) degraded ARG with an ACE of 5.28 and 6.09%, respectively, which were 1.26 and 1.45 times higher than Mode CC (4.2%). At the same time, the EC were 0.36 and 0.27 kWh gCOD^-1, respectively, which were 12.2 and 34.2% lower than Mode CC (0.41 kWh gCOD^-1). The parameters of Mode CC-EA were further optimized and used for the degradation of three typical dye wastewaters, crystal violet (CV), methylene blue (MB) and methyl orange (MO), to investigate their general applicability. The results showed that the optimized Mode CC-EA achieved higher decolorization rates, chemical oxygen demand (COD) and total organic carbon (TOC) removal rates for the four wastewaters, including ARG, than Mode CC within 120 min for the same total input charge. The ACE of Mode CC-EA was on average 1.3 times higher than that of Mode CC, while the EC was on average 25.3% lower. Mode CC-EA achieves efficient use of electrical energy while ensuring the catalytic effect, which is of great application for the efficient treatment of dye wastewater and significance for the industrial development of ECO technology.

Treatment of wastewater from the washing process of a municipal solid waste collection container by electrochemical treatment using different anode materials: a statistical optimization

An underground municipal solid waste (MSW) container should be washed periodically to prevent/reduce odor and leachate production. In this study, the treatment process of wastewater derived from the washing process of an MSW container was investigated using the electrochemical (EC) treatment process with different anode materials (Fe, TiO₂, and graphite). Response surface methodology (RSM) was used to evaluate the effect of process parameters such as initial pH, applied current, and reaction time on chemical oxygen demand (COD), Tannin/Lignin, and color removals. According to the results obtained from the RSM models, all process parameters were significant. The optimum process parameters in terms of COD removal were derived from the models for each anode material. Under the optimized conditions, the COD removals were determined to be 93.25%, 75.95%, and 98.46% for Fe-Fe, TiO₂-Fe, and graphite-Fe electrode pairs, respectively. The color and Tannin/Lignin removals were determined as 98.12% and 77.78% for the Fe-Fe, 92.76% and 98.45% for the TiO₂-Fe and 94.50% and 79.56% for the graphite-Fe electrode pair, respectively. The specific energy consumption (SEC) values were found as 46.95, 300.02, and 32.95 kWh/m³ for each electrode combination given above, respectively. In terms of both removal efficiencies and SEC, the most effective anode material was determined as graphite, followed by iron.

Performance of a Three-Dimensional Electrochemical Reactor (3DER) on Bisphenol A Degradation

This study constructed a three-dimensional electrochemical reactor (3DER) using meshed stainless steel sheets and titanic magnetite particles (TMP) to investigate bisphenol A (BPA) degradation through the synergistic action of electrical current and TMP. We examined some TMP characteristics, such as particle size, specific surface areas, X-ray diffraction, surface imaging, elemental constituents, and electrical resistivity. It was found that TMP was a micron-level material with excellent electrical conductivity, and it could be regarded as a magnetite-based material comprising Fe(II) and Fe(III). The single-factor experiment determined the optimal conditions for BPA removal in 3DER, specifically by introducing 200 ml of BPA-simulated wastewater (10 mg L⁻¹) into 3DER. At the initial pH of 9.00, current and electrodes gap of 300 mA and 15 mm, respectively, and adding 1 ml of 0.5 M potassium peroxymonosulfate and 1 g TMP, > 98% of BPA was removed after 55 min of electrochemical reaction. In addition, liquid chromatography–mass spectrometry identified the intermediates formed during the BPA treatment, showing two possible pathways for BPA degradation. The final degradation intermediates were chain organics with simple molecular structures. This research provided an understanding of the potential application of 3DER for BPA removal in water.

Progress in Preparation and Application of Titanium Sub-Oxides Electrode in Electrocatalytic Degradation for Wastewater Treatment

To achieve low-carbon and sustainable development it is imperative to explore water treatment technologies in a carbon-neutral model. Because of its advantages of high efficiency, low consumption, and no secondary pollution, electrocatalytic oxidation technology has attracted increasing attention in tackling the challenges of organic wastewater treatment. The performance of an electrocatalytic oxidation system depends mainly on the properties of electrodes materials. Compared with the instability of graphite electrodes, the high expenditure of noble metal electrodes and boron-doped diamond electrodes, and the hidden dangers of titanium-based metal oxide electrodes, a titanium sub-oxide material has been characterized as an ideal choice of anode material due to its unique crystal and electronic structure, including high conductivity, decent catalytic activity, intense physical and chemical stability, corrosion resistance, low cost, and long service life, etc. This paper systematically reviews the electrode preparation technology of Magnéli phase titanium sub-oxide and its research progress in the electrochemical advanced oxidation treatment of organic wastewater in recent years, with technical difficulties highlighted. Future research directions are further proposed in process optimization, material modification, and application expansion. It is worth noting that Magnéli phase titanium sub-oxides have played very important roles in organic degradation. There is no doubt that titanium sub-oxides will become indispensable materials in the future.

Enhanced struvite generation and separation by magnesium anode electrolysis coupled with cathode electrodeposition

Adding magnesium ions (Mg²⁺) to produce struvite is an important method to recover nitrogen and phosphorus from wastewater. Both the Mg²⁺ source and subsequent separation of struvite are key factors for the utilization of struvite. In this study, we developed an efficient method to recover nutrient salts from wastewater using sacrificial Mg anodes to generate struvite, with its simultaneous separation through cathode electrodeposition. The anode-released Mg²⁺ reacted with NH₄⁺-N and PO₄^3--P in bulk solution to form struvite, which was more intense on the cathode surface due to the relatively higher pH environment from hydrogen evolution, resulting in most of the struvite being deposited on the cathode surface and simultaneously separated out of the bulk solution. Using a cathode with a higher solution-cathode interface area and relatively low current density facilitated struvite deposition. Results showed that under optimal electrolysis condition (5.76 A/m², pH 8.5, 180 min, and 1.2:1.0 Mg:P), 91% of the undissolved substances as the phosphate precipitation were deposited on the graphite cathode surface, and the proportion of struvite in the deposition reached 41.52%. This study provides a novel electrochemical method for struvite synthesis and separation for the recovery of nitrogen and phosphorus from wastewater.

Magnetically assembled electrodes based on Pt, RuO2-IrO2-TiO2 and Sb-SnO2 for electrochemical oxidation of wastewater featured by fluctuant Cl- concentration

Magnetically assembled electrode (MAE) flexibly attracts magnetic particles (auxiliary electrodes, AEs) on a main electrode (ME) by the magnetic force, where the role of ME is always ignored. In this study, Ti/Pt, Ti/RuO₂-IrO₂-TiO₂ and Ti/Sb-SnO₂ were selected as the ME for comparison in treating synthetic wastewater (acid red G or phenol) with variable Cl^- content. The effects of ME type, loading amount of Fe₃O₄/Sb-SnO₂ AEs, and Cl^- concentration were investigated, followed by varied electrochemical characterizations. Results show that AEs played a vital role in electrode activity and selectivity, and MEs also exerted an unignorable influence on the performance of the MAEs. Among the three MEs, Ti/RuO₂-IrO₂-TiO₂ has the best OER/CER ability, activating more extra active sites with same AEs loading amount, leading to higher organics degradation efficiency under chlorine-free condition. However, this MAE is featured by the noticeable accumulation of intermediate products under chlorine-free condition even if 0.3 g·cm^-2 of AEs are loaded. All electrodes' performances were enhanced in the presence of Cl^-. With high concentration chloride (0.5 M NaCl), the accumulation of intermediate products was reduced significantly, especially on Ti/RuO₂-IrO₂-TiO₂ based MAE, and no chlorinated compound was identified. Finally, the structure-activity relationships of these MAEs were proposed.

Evaluation of diclofenac degradation effect in "active" and "non-active" anodes: A new consideration about mineralization inclination

This work investigates the electrochemical oxidation (EO) of diclofenac (DCF) in water with Ti/Ti₄O₇, Ti/Ru-Ir, Ti/Sb-SnO₂ and Ti/PbO₂ electrodes. Scanning electron microscope and X-ray diffraction results suggest that Ti/Ti₄O₇ has porous stacked surface morphology and Ti/Sb-SnO₂ possesses the smallest grain size. Linear sweep voltammetry test results indicate that PbO₂ has the highest oxygen evolution potential, while Ti/Ti₄O₇ and Ti/Ru-Ir show better oxygen evolution activity. DCF degradation results reveal that PbO₂ possessed the highest DCF removal (R_DCF = 99.2%) and chemical oxygen demand (COD) removal (R_COD = 97.0%), the fastest COD degradation rate (k = 0.0275 min^-1, R² = 0.964), the lowest specific energy consumption (EC_DCF = 1.81 kWh^.g DCF^-1, EC_TOC = 6.90 kWh^.g TOC^-1). The toxicity variation of DCF during EO process on PbO₂ is rise first and then to fall. Considering the differences of the four electrodes in residual, conversion and mineralization aspects, mineralization selectivity (MS) was proposed to estimate the mineralization inclination of electrodes during EO process, and PbO₂ displays the strongest mineralization inclination (MS = 0.594). In addition, the possible degradation pathway of DCF on PbO₂ electrode indicates a composite behavior of conversion and mineralization. All of them above indicate the promising application potential of PbO₂ in lower concentration pharmaceuticals and personal care products wastewater treatment. Moreover, MS could be employed as a supplementary index to assess the different inclinations of this composite behavior on various electrodes used for electrochemical treatment of organics in later studies.

Hydraulic Characteristics, Residence Time Distribution, and Flow Field of Electrochemical Descaling Reactor Using CFD

This paper uses computational fluid dynamics (CFD) to simulate flow field distribution inside an electrochemical descaling reactor in three dimensions. First, the reactor flow field was obtained by steady-state simulation, and the grid independence was verified. Then, the steady state of the flow field was judged to ensure the accuracy of the simulation results. Transient simulations were performed on the basis of steady-state simulations, and residence time distribution (RTD) curves were obtained by a pulse-tracing method. The effects of plate height and plate spacing on reactor hydraulic characteristics (flow state and backmixing) were investigated using RTD curves, and the results showed that increasing the plate height and decreasing the plate spacing could make the flow more similar to the plug flow and reduce the degree of backmixing in the reactor. The flow field details provided by CFD were used to analyze the reactor flow field and were further verified to obtain the distribution patterns of dead and short circuit zones. Meanwhile, information regarding pressure drops was extracted for different working conditions (490, 560, and 630 mm for pole plate height and 172.6, 129.45, and 103.56 mm for pole plate spacing), and the results showed that increasing the pole plate height and decreasing the pole plate spacing led to an increased drop in pressure. In this case, a larger pressure drop means higher energy consumption. However, increasing the pole plate height had a smaller effect on energy consumption than decreasing the pole plate spacing.