Chem Eng 2009
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a r t i c l e i n f o a b s t r a c t
Article history: The removal of organic pollutants from a highly complex industrial wastewater by aluminum, iron
Received 31 October 2007 and aluminum + iron electrocoagulation systems was evaluated. Under optimal conditions of pH 8 and
Received in revised form 14 July 2008 45.45 A m−2 current density, the electrochemical method yields a very effective reduction of all organic
Accepted 10 August 2008
pollutants. The optimal treatment (aluminum + iron) reduced chemical oxygen demand (COD) by 69%,
biochemical oxygen demand (BOD5 ) by 71%, color by 83%, turbidity by 80% and total coliforms by 99%. The
Keywords:
raw and treated wastewater was characterized by UV–vis spectroscopy and cyclic voltammetry to confirm
Combined Al–Fe electrode system
the increase in water quality. Finally, the sludge produced during electrocoagulation was characterized
Electrocoagulation
Industrial wastewater
by scanning electron microscopy (SEM) and energy dispersive X-ray analysis (EDS).
COD reduction © 2008 Elsevier B.V. All rights reserved.
1385-8947/$ – see front matter © 2008 Elsevier B.V. All rights reserved.
doi:10.1016/j.cej.2008.08.007
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2. Materials and methods The initial evaluation of the electrochemical treatment was
determined by analysis of the chemical oxygen demand (COD) and
2.1. Wastewater samples the color (465 nm, Pt/Co scale) at different time intervals. How-
ever, once the optimal conditions were found the raw and treated
Samples of wastewater were collected from a treatment plant wastewater samples were analyzed for the BOD5 and COD, color,
located at the end of an industrial park. This facility receives the pH, total coliforms, turbidity, iron and aluminum content, as indi-
industrial discharge of 144 different factories. All of the indus- cated in the Standard Methods procedures [27].
trial effluents enter the wastewater treatment plant together [18].
The actual wastewater treatment plant consists of shredders, sand 2.3.1. Cyclic voltammetric measurements
separators, oil and grease separators, primary clarifiers, biological Cyclic voltammetry of crude and treated wastewater was per-
activated sludge reactors, secondary clarifiers and a chlorine disin- formed using a standard three-electrode cell. The waveforms were
fecting unit. This treatment only achieves a 60% reduction in COD, generated by a potentiostat model Epsilon-BAS The carbon paste
which does not comply with environmental discharge standards. electrodes (CPE) were circular with a surface area of about 3.5 mm2 .
Thus, additional treatment steps are required to improve the quality The CPE was prepared from a 1:1 mixture of 99.99% pure single
of the water. crystal graphite (Alfa AESAR) and nujol oil (Fluka). The paste was
Wastewater samples were collected at the inlet of the biological transferred into a PVC tube and compacted to eliminate trapped
activated sludge reactor in plastic containers and cooled to 4 ◦ C, air then a copper conductor was inserted before the paste set. The
then transported to the laboratory for analysis and electrochemical surface of the electrode was renovated after each potential scan
treatments. [28]. The scan rate was 100 mV s−1 . The reference electrode was
an Ag/AgCl saturated with KCl and the counter electrode was a
2.2. Electrochemical reactors platinum wire.
Three different electrochemical reactors were used in this study. 2.3.2. UV–vis spectrometry
The main difference among them is the anodic material. The alu- UV–vis spectra were obtained from samples of raw and treated
minum and iron reactors have the same characteristics; both of wastewater using a double beam PerkinElmer 25 spectropho-
them are batch monopolar electrochemical reactors which con- tometer. The scan rate was 960 nm s−1 within the 200–700 nm
tain an array of 10 parallel electrodes. Each electrode has 0.11 m wavelength range. The samples were scanned in quartz cells with
long and 0.06 m wide which gives an area of 0.0132 m2 each a 1 cm optical path.
and a total anodic area, Aa of 0.066 m2 . A 4 dm3 recipient served
as the supply vessel for the reactor. A dc power source sup- 2.3.3. Thermodynamic analysis
plied the system with 1–4 A at 8 V, corresponding to a current The existence of aluminum and iron complexes in aqueous
density of 15.15–60.60 A m−2 . The electrochemical reactor with solution has been reported [29,30]. Using this information the dis-
aluminum–iron anodes contains an array of 12 parallel electrodes; tribution diagrams of chemical species were calculated using the
6 aluminum and 6 iron electrodes, alternating the aluminum and MEDUSA program [31].
iron. Each electrode is 0.11 m long and 0.06 m wide for an area
of 0.0132 m2 each and a total anodic area, Aa of 0.0792 m2 . The 2.3.4. Sludge characterization
volume of the reactor is 4 dm3 , the dc power source supplied the The sludge generated by the electrochemical technique was ana-
system with 1–4 A at 13 V, corresponding to a current density of lyzed by scanning electron microscopy (SEM) and energy dispersive
12.62–50.5 A m−2 . After various elapsed times, samples were taken. X-ray microanalysis (EDS). The analysis was performed on a Phillips
A schematic diagram of the electrochemical reactors is shown in XL-30 microscope to observe the composition and configuration of
Fig. 1. the structure. SEM provides images of rough material with resolu-
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Table 1
Physicochemical characteristic of the raw industrial wastewater
Fig. 2. Effect of pH on COD reduction by Al electrode reactor, applying 3 A of direct Fig. 4. COD removal from wastewater at different current densities by Al electrode
current with a treatment time of 60 min. reactor, wastewater pH of 8 and treatment time of 60 min.
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Fig. 5. COD reduction in wastewater as a function of treatment time by Fe electrode reactor at different initial pH, and applying 3 A of direct current with a treatment time
of 60 min. Before (a) and after (b) precipitation of iron hydroxides with NaOH.
different possible Al chemical species present in aqueous solu- experimental conditions of 3 A of current and 60 min of electroly-
tion. sis along with the Faraday constant and the charge on the cation
The chemical dissolution process corresponds to the oxidation (z = + 3), it is possible to calculate the maximum amount of Al, in
of the aluminum plates with the simultaneous reduction of water this case 0.036 mol or 972 mg:
to form hydrogen [34], as shown in Eq. (1):
It
n= (6)
2Al(s) + 6H2 O → 2Al 3+
(aq) + 3H2(g) + 6OH(aq) −
(1) zF
The Al concentration in solution can be calculated using Eq. (7):
On the other hand, the electrochemical processes that occur
on the anode and on the cathode surfaces are represented in Eqs. n
[M] = (7)
(2)–(4). On the anode, aluminum dissolution and oxygen evolu- V
tion can compete. On the cathode, hydrogen evolution is the main where n is the number of moles and V is the volume (4 dm−3 )
expected reaction. of the reactor. The maximum expected Al concentration is thus
242 mg dm−3 . A particular effect that has been recently noted is
Al(s) → Al3+ (aq) + 3e− (2)
the so-called “superfaradaic efficiencies”. This term describes the
+ − difference between the theoretical amount of aluminum in aqueous
2H2 O → O2(g) + 4H (aq) + 4e (3)
solution and the actual Al detected. The detected Al concentra-
H2 O + e− → (1/2)H2(g) + OH− (aq) (4) tion in aqueous solution in the mixed solution is 358 mg dm−3
(previous to settling). The theoretical calculation corresponds to
The cathode may also be chemically attacked by OH− ions gen-
242 mg dm−3 , which implies that there is an excess of 50%. A pos-
erated during H2 evolution at high pH.
sible explanation of this difference is that a chemical process takes
2Al + 6H2 O + 2 OH− → 2Al (OH)4 − + 3H2 (5) place at the cathode promoting aluminum dissolution. The electro-
chemical oxidation and reduction of water can modify the pH on
The aluminum and hydroxide ions generated by electrode reactions
react to form Al(OH)3(s) .
Using Faraday’s law to calculate the maximum amount of Al
produced in the electrochemical process in Eq. (6) and with the
Fig. 6. Iron(II) species distribution diagram in wastewater as a function of pH. The Fig. 7. COD removal from wastewater in time in Fe reactor at different current
concentration of iron is [Fe2+ ]TOT = 18.0 mM. densities, wastewater pH of 8 and treatment time of 60 min.
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Fig. 8. COD reduction in wastewater in time by Al + Fe electrode reactor at different initial pH, and applying 3 A of direct current with a treatment time of 60 min. Before (a)
and after (b) precipitation of iron hydroxides with NaOH.
the anode and cathode surfaces with respect to the bulk pH. This The total coliforms, color and turbidity concentration were
is especially important on the cathode, where the pH can become reduced by 99%, 81% and 80%, respectively.
strongly alkaline. This can justify the important contribution of the The iron concentration in wastewater plays an important role
aluminum chemical dissolution in the cathode to the total dissolu- in pollutant removal. Concentration and pH define the different
tion rate [6]. possible iron chemical species present in aqueous solution. Using
Faraday’s law to calculate the maximum amount of Fe2+ produced
in the electrochemical process in Eq. (6), with the experimental
3.3. Electrocoagulation using the iron anodes electrochemical conditions of 3 A of current and 60 min of electrolysis along with the
reactor Faraday constant and the charge on the cation (z = + 2), it is possible
to calculate the maximum amount of Fe2+ to be 0.056 mol or 3.12 g.
In the case of iron anodes, wastewater samples were taken at The iron concentration in solution can be calculated using Eq.
different treatment times, as shown in Fig. 5, the best conditions (7): where n is the number of moles and V is the volume (3 dm−3 )
to obtain insoluble chemical specie starts at pH 9. Therefore, we of the reactor. The maximum concentration is thus 1042 mg dm−3
present two figures to show how the COD removal rate can be Fe2+ . A particular effect that has been recently noted is the so-called
modified if the final pH is adjusted. “superfaradaic efficiencies”. The detected Fe concentration in aque-
Fig. 5a and b shows the COD removal as a function of treatment ous solution in the mixed solution is 1150 mg dm−3 (previous to
time at different initial wastewater pH values. After certain elapsed settling). The theoretical calculation corresponds to mg dm−3 ; this
times, samples were taken and the supernatant (Fig. 5a) analyzed. implies that there is an excess of 10%.
At the same time, another set of samples were adjusted to final pH Electrocoagulation of wastewater using iron electrodes takes
9.5 using NaOH for precipitating iron hydroxides (Fig. 5b). place according to the following reactions [38]:
Fig. 5a shows that the maximum COD removal occurs at
pH 8 (53%) and the lowest at pH 12. Fig. 5b shows that
if pH is adjusted to 9.5, increasing precipitation, COD reduc-
tion increases, with the maximum reduction still at pH 8
(70%).
It is generally accepted that iron hydroxyl complexes form
after the initial oxidation at the anode and the highly insolu-
ble compound Fe(OH)2 is the predominant specie over a wide
pH range [35]. These results agree with previous research [36,37]
that at pH 5–9, the majority of iron complexes (coagulants)
are formed and this is the optimum pH range for carrying out
electrocoagulation. The minimum COD reduction was at pH 2,
since hydroxide ions generated at the cathode were neutralized
by H+ ions, limiting the formation of iron hydroxide complexes
(Fig. 6).
As previously discussed, COD reduction is quite similar from
pH 4 to 8. Since the actual pH of the wastewater is around 8, fur-
ther experiments were performed in this condition but final pH is
adjusted to 9.5, to improve the hydroxide precipitation.
Fig. 7 shows the variation of the COD as a function of current den-
sity, note that the best removal rate is achieved under 45.45 A m−2
(70%) and no significant increase in the COD removal is observed Fig. 9. COD reduction in wastewater in an Al + Fe reactor at different current densi-
when the current density is increased to 60.6 A m−2 (73%). ties, wastewater pH of 8 and treatment time of 60 min.
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Anodic reaction:
Cathodic reaction:
Solution reaction
Overall reaction:
In the cases of the reactor with both aluminum and iron anodes,
wastewater samples were taken at specific treatment times as
shown in Fig. 8. The best conditions for forming the insoluble iron
complex starts at pH 9. Since final pH affects iron complex pre-
cipitation, analysis was done both straight out of reactor and after Fig. 10. Cyclic voltammograms recorded at the 3.5 mm2 CPE over a potential win-
treatment with NaOH as shown in Fig. 8a and b. dow of −1.5 to 1.45 V of the raw, aluminum, iron, and aluminum + iron treated
wastewater.
As shown in Fig. 8, minimal COD reduction occurs when the
initial pH is 2 or 12 and the maximum is at pH 8. In addition, post-
The reactions that are taking place are show below:
treatment addition of NaOH to encourage precipitation of the iron
hydroxides, increases the maximum COD removal from 50% to 69%.
Anodic reactions:
The distribution diagram of aluminum and iron chemical species
calculated from the MEDUSA program gives the same results as Al(s) → Al3+ (aq) + 3e− (12)
shown in Figs. 3 and 6. At low pH the aluminum ion is the predom-
inat specie in solution, from pH 3.3 to 10.0 Al(OH)3(s) is the most Fe(s) → Fe2+ (aq) + 2e− (13)
abundant chemical specie in the solution; however, above pH of 10 Cathodic reaction:
the soluble Al(OH)4 −1 appears in the solution causing the rediso-
lution of sludge. The iron species are: Fe2+ dominates up to pH 7.5, 2H2 O(l) + 2e− → 2OH− (aq) + H2(g) (14)
after which Fe(OH)2(s) remain. Solution reactions:
Since the COD reduction is quite similar from pH 4 to 8 and
the actual pH of the wastewater is around 8, the experiments were Fe2+ (aq) + 2OH− (aq) → Fe(OH)2(s) (15)
performed at that pH, but afterwards adjusted to about 9–10 to
Al3+ (aq) + 3OH− (aq) → Al(OH)3(s) (16)
improve the iron hydroxide precipitation.
The variation of the COD as a function of current density is shown Overall reaction:
in Fig. 9. The optimum reduction is achieved at 37.87 A m−2 (69%)
Fe(s) + Al(s) + 2H2 O(l) → Fe(OH)2(s) + Al(OH)3(s) + H2(g) (17)
with only a slight increase when the current density is increased to
50.5 A m−2 (71%).
The aluminum + iron combined electrochemical treatment
reduces total coliforms, color and turbidity by 99%, 83% and 80%,
respectively.
Using Faraday’s law in Eq. (6), with the experimental conditions
of 3 A of current and 60 min of electrolysis along with the Faraday
constant and the charge on the cation (z = + 3), the calculated max-
imum amount of Al is 0.036 mol or 972 mg. The Al concentration in
solution is calculated using Eq. (7) to be 242 mg dm−3 .
Likewise, the calculated maximum amount of Fe2+ is 0.056 mol
or 3.12 g and the corresponding maximum concentration is
782 mg dm−3 Fe2+ .
The detected Fe and Al concentration in aqueous solution in
the mixed solution were found to be quite similar to the expected
theoretical values.
Table 2
COD reduction kinetics, using first- and second-order equations
Table 3
A comparative results obtained by the three anodic experiments.
Fig. 12. Micrographs and elemental analysis of the sludge generated by aluminum (a), iron (b), and aluminum + iron and (c) electrocoagulation process.
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3.6. Comparative results iron was more effective in reducing COD, therefore the optimum
practice is to combine aluminum + iron for obtaining high COD and
Once the optimal conditions were found the raw and treated color removal efficiencies.
wastewater samples were analyzed using the BOD5 and COD, total
coliforms and turbidity. Table 3 shows the efficiencies obtained. Acknowledgements
Both aluminum and iron are almost equally effective in reducing
fecal coliforms and turbidity. However, aluminum was found to be The authors wish to acknowledge support given by the Uni-
more effective in removing color than iron. versidad Autónoma del Estado de Mexico, especially the Facultad
However, aluminum was found to be more effective in remov- de Química (projects 2452/2007 and 2425/2007) and the SNI for
ing color than iron and iron was more effective in reducing COD. supporting research.
The effluent treated with iron as the sacrificial anode appeared yel-
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