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

Chemical oxygen demand and tannin/lignin removal from paper mill wastewater by electrocoagulation combined with peroxide and hypochlorite treatments

The present investigation sought to assess the practicality of utilizing a combined pre-treatment approach comprising electrocoagulation, peroxide, and hypochlorite treatments for the removal of chemical oxygen demand (COD) and tannin/lignin from paper mill wastewater. The study aimed to optimize the operating parameters with a view to maximizing the removal efficiencies while minimizing energy consumption. A pair of iron electrodes were used as anode and cathode in the study, and the main operating parameters were determined as initial pH, applied current, treatment time and oxidant dosage/COD ratio. Response surface methodology (RSM) was used to evaluate the effect of these parameters on COD and tannin/lignin removals. The primary findings of the investigation indicated that the integration of electrocoagulation with peroxide and hypochlorite treatments exhibited efficacy in removing COD, tannin/lignin, colour, phenol, and turbidity from paper mill wastewater. The optimized conditions resulted in COD removal efficiencies of 48.13 ± 2.2% and 29.53 ± 1.4% for EC with H2O2 and Ca(OCl)2, respectively. Tannin/lignin removal efficiencies were 92.59 ± 3.6% and 94.09 ± 1.8% for EC-H2O2 and EC-Ca(OCl)2, respectively. The specific energy consumption (SEC) values showed that EC-Ca(OCl)2 required 7 times more energy than EC-H2O2 for removing 1 kg COD. The principal deduction drawn from the study was that EC-H2O2 pre-treatment demonstrated superior COD removal efficiency and lower energy consumption, while EC-Ca(OCl)2 pre-treatment exhibited greater efficiency in removing toxic and recalcitrant pollutants. In future studies, it would be useful to conduct research to increase COD removal efficiency in addition to tannin/lignin removal in EC-Ca(OCl)2 process.

Treatment and optimization of high-strength egg-wash wastewater effluent using electrocoagulation and electrooxidation methods

Egg-washing wastewater contains a high concentration of nutrition and organic matter since eggs are broken during the washing and cleaning processes. Moreover, the wastewater contains small amounts of detergents or sanitizing agents. These contaminants may pose environmental challenges when they are not properly managed or treated. The study scrutinizes the efficiency of electrocoagulation (EO) and electrooxidation (EO) approaches for egg-wash wastewater treatment. The response surface methodology was employed to optimize the operational parameters. The removal efficiencies of soluble chemical oxygen demand (sCOD 90%), ammonia (NH3-N 91%), nitrate (NO3--N 97%), nitrite (NO2--N 89.3%), total dissolved nitrogen (TDN 91%), and phosphate (90%) were measured under various treatment conditions. The optimum treatment conditions achieved in the combined EC + EO process were pH 6.0, current density 20 mA cm-2, and electrolysis time of 60 min, respectively. Degradation kinetics of the egg-wash pollutants showed a significant reduction in half-life (t1/2) with EO (after EC-Aluminum) at 15 min, 12 min, 17 min, and 15 min for sCOD, NO2--N. NO3--N, and TDN, respectively. Whereas the half-life of NH3-N (18 min) and phosphate (17 min) reduced significantly with the EO (after EC-iron). Al and Fe electrodes coupled with boron-doped diamond were found efficient for pollutant removal. Environmental implication. Egg-wash wastewater has a high protein content and contains nutrients that are essential for living organisms. While these compounds can be valuable for agricultural use by increasing soil phosphate concentration, they can also become an issue if the excess nutrients are not properly managed. The soil has a threshold limit for holding phosphate, and any excess amount may be transported through surface runoff or contaminate groundwater through leachate, potentially affecting aquatic ecosystems and water quality. This study explores the efficiency of electrocoagulation and electrooxidation methods in treating egg-wash wastewater. These methods aim to remove pollutants and reduce their environmental impact.

Treatment of galvanic effluent through electrocoagulation process: Cr, Cu, Mn, Ni removal and reuse of sludge generated as inorganic pigment

Galvanic effluents are composed of a wide range of heavy metals, requiring adequate treatment to remove these contaminants and to meet the limits established by environmental agencies. Considering this aspect, the present study had as main objectives: (i) to evaluate the efficiency of the electrocoagulation (EC) in the treatment of a galvanic effluent, with the purpose of removing total Cr, Cu, Mn, Ni and (ii) reuse the sludge generated for inorganic pigment production. EC tests were carried out through factorial design 2³ with triplicate central point. pH (3, 7, 11), reaction time (15, 22.5 and 30 min) and current density (10, 17.5 and 25 mA/cm²) were the control variables. Under ideal experimental conditions (pH 7.00; t = 22.5 min and DC = 17.5 mA/cm²) were removed 96.94% of Mn, 97.63% of Cu and 99.99% of total Cr and Ni, allowing to meet the limits provided in CONAMA Resolution 430/2011. The production of inorganic pigments from a mixture of 10% sludge (generated in the ideal experimental condition) and Al₂O₃ and TiO₂ proved to be technically viable. It was obtained 8.27 g of a brown inorganic pigment, composed mainly of Al_1.82Cr_0.18O₃, Ca_0.999(Ti_0.805Fe_0.201)O_2.899 and Fe_2.18O₄Ti_0.42. Therefore, the results obtained demonstrate that EC is an effective technique in galvanic effluents treatment. The sludge generated in this process showed to be appropriated to be reused in inorganic pigment production and could be considered as an alternative to reduce the environmental impact related to electroplating process.

Electrocoagulation for nutrients removal in the slaughterhouse wastewater: comparison between iron and aluminum electrodes treatment

The poultry slaughterhouse wastewater has a high pollutant load, mainly organic matter, and nutrient content. The nitrogen and phosphorus discharge can cause eutrophication of the receiving water bodies. Electrocoagulation has been studied for several pollutants removal from different sources. The objective of this work was to evaluate the electrocoagulation process in the poultry slaughterhouse wastewater treatment using both iron and electrodes to remove total nitrogen and phosphorus. After the raw and polished wastewater characterisation, a 2³ Central Composite Rotatable Design was applied to evaluate the current density, initial pH, and electrocoagulation time influence on the nutrients removal and to find the optimum condition of nutrients removal. Once the optimum condition for nutrient removal was stablished, other physicochemical, microbiological, and ecotoxicological parameters, as well as the treatment cost, were investigated to determine which electrode material was the most efficient. For raw wastewater, applying the optimum treatment condition of 20 mA cm^-2 current density, initial pH 6.2, and time of 20 min, the nitrogen and phosphorus removal presented similar for both electrode materials. Besides being cheaper ($ 4.13 m^-3), iron electrode treatment presented better Chemical Oxygen Demand, oils and greases, solids, and ecotoxicity removal. For polished wastewater, the treatment with aluminum electrode was more efficient under the applied current density of 30 mA cm^-2, initial pH 8 and time of 10 min, obtaining the lowest cost $ 3.89 m^-3. In the iron electrode case, the final pH exceeds the limits established by local legislation requiring correction for release into water bodies.

Chitosan-Terephthalic Acid-Magnetic Composite Beads for Effective Removal of the Acid Blue Dye from Aqueous Solutions: Kinetics, Isotherm, and Statistical Modeling

A terephthalic acid-modified chitosan-magnetic nanocomposite (Cs-Tp@Fe₃O₄) was synthesized and characterized. The synthesized Cs-Tp@Fe₃O₄ was used in a batch process for the adsorptive removal of the acid blue 25 (AB-25) dye in aqueous solutions. The kinetic data were subjected to the pseudo-first-order, pseudo-second-order, Elovich, and intra-particle diffusion models, while the equilibrium data were evaluated with the Langmuir, Freundlich, Temkin, and Dubinin-Radushkevich isotherm models. The effects of the initial dye concentration, contact time, and adsorbent dosage, as well as their interactions, on the removal efficiency were investigated using the design of experiments based on a central composite design, and the resultant data were modeled with the response surface methodology (RSM), artificial neural network (ANN), adaptive neuro-fuzzy inference system (ANFIS), and multiple linear regression (MLR) approaches. The adsorption process followed pseudo-first-order with good agreement between the experimental Q _e(exp) and calculated Q _e(cal.) amounts of dye adsorbed, as well as the values of correlation coefficient, R ² (0.999) and percentage of sum square error, % SSE (0.640). All the investigated adsorption isotherms fitted all models well in the order of Dubinin-Radushkevich > Langmuir > Freundlich > Temkin with R ² > 0.9 with the monolayer maximum adsorption capacity of 440.24 mg/g obtained from the Langmuir isotherm. The RSM model predicted the maximum removal efficiency at an optimum initial dye concentration of 19.11 mg/L, a contact time of 95.3 min, and an adsorbent dosage of 0.18 g. Statistically, the models were fitted in the order of RSM > ANN > ANFIS > MLR. These results indicated that the prepared Cs-Tp@Fe₃O₄ is an efficient adsorbent for the AB-25 dye removal with excellent stability for water treatment applications.

Electrocoagulation treatment of shale gas drilling wastewater: Performance and statistical optimization

Shale gas drilling wastewater is a challenging waste stream generated in gas industries. It is a mixture of different organic and inorganic compounds. Treatment of this complex wastewater relies on a suitable technology for the removal of small suspended particles and dissolved elements. This study employed electrocoagulation (EC) as an efficient method for shale gas drilling wastewater pretreatment. The optimum operating conditions for turbidity, TOC, and Ca²⁺ removal were determined using a response surface methodology (RSM). The chloride (Cl^-) removal and residual iron of effluent in the EC process were also tested and evaluated. Based on the analysis of variance (ANOVA), the coefficient of determination (R²) was calculated and found to be above 0.86 for all the responses. The maximum removal efficiencies were found to be around 98.3%, 78.5%, and 56.5% for turbidity, TOC, and Ca²⁺ removal under the optimum conditions, respectively. In order to treat drilling wastewater by EC process both efficiently and economically, the following operating parameters are recommended: 318 A/m² for current density, 20 min for reaction time and 4.4 for initial pH. A total operation cost of 0.80 US$/m³ was estimated under these conditions.

Treatment of cardboard factory wastewater using ozone-assisted electrocoagulation process: optimization through response surface methodology

Cardboard factory wastewater is usually known by high chemical oxygen demand (COD), color, phenols, lignin, and its derivatives, and usual treatment techniques are not able to treat such wastewaters. This study aimed to investigate the efficiency of ozone-assisted electrocoagulation process (EC/O₃) for the treatment of real cardboard wastewater. The parameters influencing COD removal in the EC/O₃ process were optimized using response surface methodology. Regard to the statistical model, the optimum conditions were obtained at current density 9.6 mA/cm², time 20 min, and pH 12. At optimal condition, EC/O₃ process removed 74.7% and 97.5% of COD and color, which was higher compared to ozonation and EC processes separately. The COD removal followed pseudo-first-order kinetic with the coefficient correlation of 0.97 and the reaction rate constant of 0.073 1/min. To sum up, the combined electrocoagulation process with ozonation could be used satisfactorily for removing pollutants from real cardboard wastewater.

Various wastewaters treatment by sono-electrocoagulation process: A comprehensive review of operational parameters and future outlook

Electrochemical processes are a promising alternative to traditional water treatment systems because they have advantages than conventional techniques such as chemical storage, small treatment systems, no alkalinity depletion, remote adjustment, and cost-effectiveness. The most crucial electrochemical method is Electrocoagulation (EC). Through creating cationic species, the EC causes the neutralization of pollutant surface charges and destabilizes suspended, emulsified or dissolved contaminants led to attracting particles of opposite charge and form flocculants. The main drawback of the EC process is a passive film forming on the electrode surface over time. Ultrasonic (US) waves breaking down sediments formed at the electrode surface and generate high amounts of radical species to remove pollutants by creating high-pressure points inside the solution during the cavitation phenomenon. Although EC systems are considered as an exemplary renaissance in water and wastewater treatment, various parameters related to these types of systems in pollutant degradation have not been fully addressed. To present a comprehensive vision of the current state of the art, and progress the treatment efficiency and agitate new studies in these fields, this review aimed to provide an overview of electrocoagulation's application in pollutant degradation, besides the advantages, associated disadvantages and further strategies for improving the performance of this technique. Moreover, this review discussed various parameters affecting the EC/US process, including nanoparticles addition, electrolyte concentration, current intensity, electrode distance, temperature, oxidant addition, pH, pollutant concentration, reaction time, and electrode combination, chloride addition, and ultrasonic frequency. Also, the efficiency of the EC/US process for disinfection, as well as treatment of car-washing, textile, pulp, and paper industry, oily, brewery wastewater, surfactant, humic acid, and heavy metals, are addressed.

Optimization of microemulsion cleaning sludge conditions using response surface method

Microemulsion cleaning method has been proved to be an effective way to clean oily sludge with low interfacial tension and high solubilizing ability for non-miscible liquids. In this paper, the percentage range of the microemulsion in the formulation was obtained by studying phase behavior of the microemulsion. The response surface method was used to model and optimize the microemulsion to obtain the best formulation: n-BuOH content at 9.89%, NaCl content at 2.24% and AES/APG ratio at 3.75, and the oil removal rate reached 97.28%. Meanwhile, the cleaning conditions of oil sludge were also optimized by the response surface method and the optimal cleaning parameters were determined as liquid-solid ratio at 4.2, stirring rate at 157 r·min^-1, and stirring time at 38 min. In addition, some experiments were carried out to confirm the simulation results, affording the oil removal rate of 98.79%. SEM and FTIR confirmed that the oil on the sludge can be removed by microemulsion.

Modifying graphite felt cathode by HNO3 or KOH to improve the degradation efficiency of electro-Fenton for landfill leachate

Based on graphite felt (GF), the cathode of an electro-Fenton (EF) system was modified by HNO₃ and KOH respectively to improve the degradation efficiency for actual landfill leachate. The results of Fourier transform infrared spectroscopy (FTIR) spectra, Boehm titration experiments, contact angle, scanning electron microscopy (SEM) and adsorption experiments illustrated that the surface of the modified GFs had more oxygen-containing functional (OG) groups, and possessed better hydrophilicity and larger specific surface area. In 180 min H₂O₂ electrogeneration experiments, the cumulative amount of H₂O₂ produced by unmodified GF (GF-0), HNO₃ modified GF (GF-1) and KOH modified GF (GF-2) was 526 mg/L, 891 mg/L and 823 mg/L respectively. In 180 min EF reaction, the removal rate of chemical oxygen demand (COD) in GF-0, GF-1 and GF-2 EF systems was 31.88%, 60.65% and 52.08% respectively; the removal rate of NH₄ ⁺-N in GF-0, GF-1 and GF-2 EF systems was 43.37%, 98.10% and 94.81% respectively. In addition, both the performance of GF-1 and GF-2 for Fe²⁺ regeneration was greatly enhanced, and GF-1 was superior to GF-2. The degradation efficiency for landfill leachate was enhanced obviously by employing the modified EF system, suggesting that the two modified cathodes have great potential in practical production.

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.