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An economical electrocoagulation process of a hazardous anionic azo dye wastewater with the combination of recycled electrodes and solar energy

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Abstract

The energy and electrode costs are the restrictions of applying electrocoagulation (EC) in wastewater treatment and many attempts have been made to decrease these costs. In this study, an economical EC was investigated to treat a hazardous anionic azo dye wastewater (DW) that threatens the environment and human health. Firstly, an electrode for EC process was produced from recycled aluminum cans (RACs) by remelting in an induction melting furnace. The performance of the RAC electrodes in the EC was evaluated for COD, color removal, and the EC operating parameters such as initial pH, current density (CD), and electrolysis time. Response surface methodology which is based on central composite design (RSM-CCD) was used for the optimization of the process parameters which were found to be pH 3.96, CD 15 mA/cm2, and electrolysis time 45 min. The maximum COD and color removal values were determined as 98.87% and 99.07%, respectively. The characterization of electrodes and the EC sludge was conducted by XRD, SEM, and EDS analyses for the optimum variables. In addition, the corrosion test was conducted to determine the theoretical lifetime of the electrodes. The results showed that the RAC electrodes show an extended lifetime as compared to their counterparts. Secondly, the energy cost required to treat DW in the EC was aimed to decrease by using solar panels (PV), and the optimum number of PV for the EC was determined by the MATLAB/Simulink. Consequently, the EC with low treatment cost was proposed for the treatment of DW. An economical and efficient EC process for waste management and energy policies was investigated in the present study which will be instrumental in the emergence of new understandings.

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Data availability

Data will be made available on request.

Abbreviations

DC:

Direct current

EC:

Electrocoagulation

CD:

Current density

Time:

Electrolysis time

RSM :

Response surface methodology

CCD:

Central composite design

RAC:

Recycling aluminum cans

Fe:

Iron

Al:

Aluminum

ANOVA:

The analysis of variance

CR:

Congo Red

COD:

Chemical oxygen demand

SEM :

Scanning electron microscope

FESEM:

Field-emission scanning electron microscope

FTIR:

Fourier transform infrared spectroscopy analysis

XRD:

X-ray diffraction

EDS:

Electron dispersive spectroscopy

OC :

Operating cost

ENC:

Electrical energy consumption

ELC:

Electrode consumption

EC-F:

Electrocoagulation-flotation

DW:

Dye-containing wastewater

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Acknowledgements

In the study, a copper mold manufactured in the NEU-BAP project numbered 211219005 was used to obtain RAC electrodes. Some portions of information contained in this publication are printed with the permission of Minitab, LLC. All such material remains the exclusive property and copyright of Minitab, LLC. All rights reserved.

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Gülizar Kurtoğlu Akkaya: conceptualization; methodology; investigation; data curation; writing—original draft; writing—review and editing; visualization; project administration. Gökhan Polat: conceptualization; methodology; investigation; writing—original draft; writing—review and editing, visualization. Gamze Nalçacı: methodology; investigation; writing—original draft; writing—review and editing; visualization. Yasin Ramazan Eker: conceptualization, investigation, writing—review and editing.

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Correspondence to Gülizar Kurtoğlu Akkaya.

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Akkaya, G.K., Polat, G., Nalçacı, G. et al. An economical electrocoagulation process of a hazardous anionic azo dye wastewater with the combination of recycled electrodes and solar energy. Environ Sci Pollut Res 30, 70331–70347 (2023). https://doi.org/10.1007/s11356-023-27375-6

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