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Ind. Eng. Chem. Res.

2007, 46, 6189-6195 6189

Study of the Electrocoagulation Process Using Aluminum and Iron Electrodes


Pablo Cañizares, Carlos Jiménez, Fabiola Martı́nez, Cristina Sáez, and Manuel A. Rodrigo*
Department of Chemical Engineering, Facultad de Ciencias Quı́micas, UniVersidad de Castilla La Mancha,
Campus UniVersitario s/n, 13005 Ciudad Real, Spain

In this work, the electrocoagulation process using aluminum and iron electrodes has been used to treat synthetic
wastewaters polluted with three different types of pollutant models: kaolin suspensions, dye solutions, and
oil-in-water emulsions. It was obtained that both electrodes can achieve high efficiencies (above 80%) in the
treatment of the three wastes. However, there are strong differences in the electrochemical coagulation or
breakup mechanism that can be explained in terms of the speciation of the dissolved metals and especially
in terms of the significant concentrations of monomeric and polymeric ionic species that appear in the treatment
with aluminum electrodes. In every case, sweep coagulation explains the coagulation of kaolin suspension
with both aluminum and iron electrodes. However, in the case of aluminum, the neutralization charge
mechanism should also be considered for low reagent doses. The coagulation of EBT (Eriochrome Black T)
solutions and the breakup of O/W emulsions (oil-in-water emulsions) have been explained by the binding of
the pollutants to metal hydroxide precipitates. This binding is promoted for aluminum electrodes because of
the adsorption of cationic reagent species on the surface of the aluminum hydroxide.

Introduction either by destabilization or by the enmeshment of the colloidal


particles in a growing hydroxide precipitate formed in the waste
Conventional chemical coagulation consists of the direct (sweep coagulation). From the theoretical point of view, two
dosing of a coagulant solution to the wastewater in order to are considered to be the main processes involved in the
reduce the electrical repulsion forces that inhibit the aggregation
destabilization of colloidal suspensions:12,13 the decrease in the
of particles. In the chemical coagulation process, the addition
thickness of the diffuse part of the electrical double layer, caused
of hydrolyzing metal salts (of Fe3+ or Al3+) as coagulant
by an increase in ionic strength, and the neutralization of the
reagents is typical. The electrochemical coagulation method,
particle charge by the specific adsorption of counterions.
on the contrary, consists of the in situ generation of coagulants
However, it is unlikely that a sufficient increase in ionic strength
by electrolytic oxidation of an appropriate anode material (e.g.,
would be a practical coagulation method.12 Hence, counterion
iron or aluminum).1,2 Recent research in wastewater treatment
adsorption is considered to be the primary mechanism in most
using electrochemically assisted coagulation has shown that this
coagulation processes. This process can be promoted by the
could be a competitive technology with the conventional
addition of monomeric or polymeric ionic reagents. In the later
coagulation process.3-11
case, the aggregation of particles can also be caused by polymer
Iron and aluminum have been widely used as electrode
bridging12 (adsorption of different functional groups of a
materials in electrocoagulation systems according to the litera-
polymer onto different colloids).
ture, because they are cheap and have been demonstrated to be
very effective on the electrocoagulation process. Depending on • Dyes as a model of soluble organic pollutants. There are
the use, one of them is preferred. Thus, for applications that many soluble organic compounds that can coagulate, ranging
are not continuous in time, aluminum electrodes are the best from simple molecules like phenol14 to more complex structures
choice,5 because iron can be oxidized easily and corrosion like dyes. The functional groups contained in the molecule and,
problems on the electrodes are reported when the cell is not particularly, their interaction with the coagulant reagents can
connected. In this context, the use of iron as the electrode explain this process for every particular case. However, in the
material has another additional problem because of the color literature, a special attention is paid to dyes, because of the huge
of Fe(III) salts. amount discharged by different types of industries.15 This group
In this work, the electrocoagulation process using aluminum consists of colored substances with a complex chemical structure
and iron electrodes has been used to treat synthetic wastewaters (many functional groups) and a high molecular weight. These
polluted with three different types of pollutant models: compounds are also highly soluble in water and are persistent
• Kaolin, as a model of colloidal pollutant, since clays behave once discharged into a natural environment. Thus, their removal
as hydrophobic colloids in water. These compounds consist of from industrial effluents is also subject of the major importance
flat sheets of alternating layers of silicon oxides and aluminum from the environmental point of view. The removal of dissolved
oxides, held together by ionic attraction for cations sandwiched organic matter by coagulation is widely reported in the
between the sheets. In water solutions, aluminum (+3) or silicon literature.16,17 Thus, two are supposed to be the primary
(+4) can be replaced with sodium (+1), potassium (+1), or mechanisms for the removal of dissolved organic matter by
ammonium (+1) ions, resulting in a negative charge of the coagulation:12,13,18 the binding of the metal species to the anionic
particle. This charge is responsible for the electric repulsion of sites of the organic molecules, neutralizing their charge and
kaolin particles and, thus, for the stability of the colloidal resulting in reduced solubility, and the adsorption of organic
suspension. The aggregation of colloids can be accomplished substances on amorphous metal hydroxide precipitates.
• Oil-in-water emulsions as a model of emulsified effluents.
* To whom correspondence should be addressed. Tel.: +34 An emulsion consists of a dispersion of one immiscible liquid
902204100. Fax: +34 926 29 53 18. E-mail: Manuel.Rodrigo@uclm.es. into another, through the use of a chemical reagent that reduces
10.1021/ie070059f CCC: $37.00 © 2007 American Chemical Society
Published on Web 08/21/2007
6190 Ind. Eng. Chem. Res., Vol. 46, No. 19, 2007

the interfacial tension between the two liquids to achieve


stability. Commonly, this chemical reagent consists of an
amphiphile molecule that contains both hydrophilic and hydro-
phobic groups. In the case of oil-in-water (O/W) emulsions,
the reagent is frequently a mineral oil. As a result of the
adsorption of this reagent, the oil droplets have a net charge on
their surfaces, which causes repulsion forces between them.
These repulsion forces between droplets explain the stability
of the emulsions. As a consequence of the small size of droplets
in the dispersion, the macroscopic appearance of the emulsion
is that of a homogeneous liquid, although this mixture is really
a heterogeneous system.19 The destabilization methods involve
the addition of coagulant agents to the wastewater, which
promote the breakup of the emulsion due to the reduction of
the superficial charge of the droplets, causing the coalescence
of the oil droplets, and the subsequent separation of the aqueous
and oily phases by means of conventional settling or dissolved-
air flotation. According to the literature,19 the main destabiliza-
tion mechanism is the attachment of adsorbing macromolecules
to more than one droplet at a time (bridging flocculation).
Destabilization by nonadsorbing polymers can also be promoted
through the mechanism of depletion flocculation. The first
Figure 1. Layout of the bench-scale plant. Detail of the electrochemical
mechanism normally involves electrically charged species as flow cell.
reagent, as these species can combine (by attractive electrical
forces) with the opposite electrically charged active sites that have a much slower reaction rate with this compound. The
are present on the surface of the droplet. particles of precipitate practically do not react with ferron.
In this work, the aim is to understand the differences obtained Therefore, this method allows distinguishing among monomeric,
in the electrocoagulation of these three models of wastewaters polymeric, or precipitate species.
as a function of the electrode material. To do that, batch The analytical measurement has been carried out by filtering
experiments have been carried out under the same operation the samples using micropore membranes of 0.45 µm to remove
conditions using iron and aluminum as electrode materials. the particles of precipitate. Once the sample is filtered, an aliquot
Results have been interpreted in terms of the species formed is added to the volume of saturated ferron solution freshly
during the metal salt hydrolysis. In addition, a study of the prepared (as ferron is not stable27) so that ferron is in excess, at
dissolution of the aluminum and iron electrodes is also carried pH 5 in an acetate buffered solution. Immediately, the absor-
out to clarify the role of the chemical dissolution on the global bance of the sample is monitored with time, until a constant
electrodissolution process. As is known, and according to the value is obtained, which is indicative of the end of the reaction.
literature,20-22 the amounts of dissolved aluminum or iron are
By plotting the logarithm of the unreacted metal (aluminum
not always in agreement with Faraday’s law. This work will
or iron) vs time, the ratio of hydrolyzing-metal species that react
help to understand this process.
quickly and slowly with ferron (that is, monomeric and
polymeric species) can be estimated. Extrapolation of the linear
Experimental Section parts of the curve to zero time yields information on the amount
Experimental Devices. The electrocoagulation experiments of metal that is bound in complexes of different degrees of
have been carried out in a bench-scale plant with a single- polymerization.23-25 The measurement of total and soluble metal
compartment electrochemical flow cell that can work in batch- (filtered with 0.45 µm) reports the ratio of soluble and precipitate
operation mode (Figure 1). Aluminum or iron electrodes were metal.
used as the anode and cathode. Both electrodes were square in Experimental Procedure. Electrochemical coagulation ex-
shape (100 mm side), each with a geometric area of 100 cm2 periments were carried out under galvanostatic conditions. Prior
and with an electrode gap of 9 mm. The electrical current was to every experiment, the electrodes were treated by rinsing with
applied using a dc power supply FA-376 Promax. The current a solution of 1.30 M HCl in order to reject any effect due to
flowing through the cell was measured with a 2000 digital the different prehistory of the electrodes.
multimeter Keithley. The wastewater was stored in a 5000 mL For the electrochemical coagulation experiments, the pollutant
glass tank stirred by an overhead stainless steel rod stirrer solution was pumped from the feed tank to the cell and then it
Heidolph RZR 2041 and thermostatized by means of a water was recirculated to the feed tank. Samples were taken at the
bath, which allowed maintaining the temperature at the desired outlet of the cell. After a time of settling (20 min in the case of
set point. The wastewater was circulated through the electrolytic kaolin and 1 h in the case of EBT and O/W emulsions), different
cell by means of a peristaltic pump. measurements were made depending on the kind of synthetic
Aluminum and Iron Speciation. The characterization of the wastewater studied:
hydrolyzed aluminum or iron species generated has been carried • In the case of kaolin, turbidity (using a 115 Velp Scientifica
out by the ferron method.23-29 This method consists of the timed turbidimeter) and pH (using an inoLab WTW pH meter) were
spectroscopy monitoring of metal (aluminum or iron) ferron (8- measured in the clarified liquid.
hydroxy-7-iodo-5-quinolinesulfonic acid) reaction, to form a • In the case of EBT, samples were first filtered and then the
complex of probable composition25 Me(ferron)3, which has a absorbance spectrum (using a UV-visible spectrophotomer
maximum absorbance of 364 nm. Monomeric species react Shimadzu UV-1603) and the pH (using an inoLab WTW pH
almost instantaneously with ferron, whereas polymeric species meter) were measured for the filtered liquid. To estimate the
Ind. Eng. Chem. Res., Vol. 46, No. 19, 2007 6191

Figure 2. Variation of aluminum and iron concentration electrogenerated


in the electrochemical processes with the electrical charge passed in batch
mode operation: [, aluminum; 0, iron; s, values predicted using Faraday’s Figure 3. Aluminum and iron dissolution rates as a function of the pH;
Law; temperature, 25 °C; initial pH, 4.8; flowrate, 50 dm3 h-1; supporting supporting media, 3000 mg dm-3 of NaCl. The onset corresponds to a
media, 3000 mg dm-3 of NaCl; volume, 1.5 dm-3. shorter range of pH for the electrochemical dissolution process using
aluminum as electrode material: [, aluminum; 0, iron.

removal of EBT, the absorbance at 550 nm (corrected by the To confirm this, Figure 3 shows the aluminum and iron
pH value) was measured (550 nm is the wavelength that shows dissolution rates versus pH in a batch reaction system when a
the maximum absorbance). sheet of 4 cm2 area (and 0.8 mm and 1.5 mm thickness,
• In the case of O/W emulsions, chemical oxygen demand respectively) is placed into a solution that contains sodium
(COD; using a Hach DR2000 analyzer) and pH (using an inoLab chloride. One can observe the presence of a minimum in the
WTW pH meter) were measured in the aqueous phase. case of aluminum at close to neutral pH and that the dissolution
To determine the amounts of aluminum and iron electrogen- rate is several orders of magnitude higher at alkaline pHs. On
erated by the applied current at the different operation condi- the contrary, in the case of iron, no minimum appears, and the
tions, as well as the hydrolysis species formed for both metals, dissolution rate increases significantly for acidic pHs. In every
several experiments were performed. In these assays, the case, hydrogen bubbles evolving from the sheet surface were
electrolyte only consists of NaCl, as well as NaOH or HCl added clearly observed, especially in the conditions in which the
for any subsequent pH adjustment (without any pollutant). After dissolution rates are higher. This observation is indicative that
the experiments, samples were monitored by the ferron method, reaction 1 is taking place for aluminum sheets and reactions 2
and aluminum or iron concentration, zeta potential, and pH were and 3 are taking place in the case of iron sheets.
then measured off-line. The aluminum and iron concentrations
were determined by dilution (50:50 v/v) of samples with HNO3 2Al + 6H2O f 2Al3+ + 3H2 + 6OH- (1)
4 N and measured using an inductively coupled plasma Liberty
Sequential Varian according to a standard method30 (plasma
Fe + 2H2O f Fe2+ + H2 + 2OH- (2)
emission spectroscopy). Zeta potential was measured using a
Zetasizer Nano ZS (Malvern, U.K.).
To study the chemical dissolution of the electrodes, some 4Fe + 10H2O + O2 f 4Fe3+ + 4H2 + 12OH- (3)
experiments were carried out in a batch operation using stirred
beakers. These beakers were initially filled with a solution of The use of the same material to be applied as the anodes and
chloride, at different pHs, and a piece of aluminum or iron was the cathodes is an important matter in electrocoagulation
placed inside. Samples were taken from the beakers, and the processes, as it allows reversing the polarity of the cell, and
pH and the aluminum or iron were measured according to the hence, this helps to minimize problems that arise from the
methods previously described. The metal dissolution rates were deposition of carbonate layers on the cathodic surface. In this
calculated after fitting the experimental data obtained in these context, it is important to note that the chemical dissolution of
essays to the mass balance equations of the batch reactor. The the electrode surfaces is promoted at alkaline pHs (for the case
initial and final weights of the metal pieces were also used to of aluminum) and at acidic pHs (for the case of iron). As is
confirm the results. known, in each electrochemical cell, there is a pH profile
between anode and cathode.3,20 On the anode, the water
Results and Discussion oxidation process generates a high concentration of protons,
resulting in a lower pH. On the cathode, the water reduction
Electrodissolution of the Aluminum and Iron Electrodes. process results in the formation of hydroxyl ions and, hence, in
Figure 2 shows the variation of the aluminum and iron a higher pH. This means that, in the case of iron-based cells,
concentrations electrogenerated in the electrochemical processes on the anode surface is going to be promoted the chemical
with the electrical charge passed, compared to the expected dissolution, while in the case of aluminum-based cells, the
values if the process was purely electrochemical (assuming the formation of coagulant on the cathode surface by chemical
only anodic process is the metal oxidation). dissolution is a subject of major importance. This was clearly
As can be seen, the electrodissolved metal concentration modeled for the case of aluminum in a previous work20 of our
increases linearly with the electrical charge for both aluminum group. According to this model, a pH close to 2.1 in the nearness
and iron, and the experimental values are greater than the values of the iron surface can explain the chemical dissolution of iron,
calculated if the process is considered to be purely electro- while a pH near 11.1 on the proximities of the cathode surface
chemical (according to Faraday’s Law). The differences ob- in the aluminum-dosage process is able to explain the super-
served between the experimental results and those expected if faradaic observation.
the process was purely electrochemical have been explained3,20,29 Electrocoagulation of a Wastewater Polluted with Kaolin.
in terms of the chemical dissolution of the electrode surfaces. Figure 4 shows the influence of the electrodic material on the
6192 Ind. Eng. Chem. Res., Vol. 46, No. 19, 2007

Figure 5. Aluminum and iron speciation (expressed as aluminum and iron


concentration) in a batch operation mode electrocoagulation assay: -×-,
monomeric species; -9-, polymeric species; -[-, precipitate; current
density, 0.5 mA cm-2; temperature, 25 °C; flowrate, 50 dm3 h-1; initial
pH, 4.5; supporting media, 3000 mg dm-3 of NaCl; volume, 1.5 dm-3.

Because of this large number of species, the quantification of


the hydrolysis rate constants, and even of the particular
speciation, is a complicated task, and there are significant
differences between the values reported in the literature.12,13,27,31-34
For this reason, in this work a simple but commonly used
method has been used to quantify the metal speciation. Thus,
Figure 5 shows the concentrations of the iron and aluminum
Figure 4. Removal of turbidity, pH, and zeta potential for an electroco- species measured by the ferron procedure in both coagulation
agulation assay of a wastewater polluted with kaolin in batch-mode operation
using as electrode material: [, aluminum; 0, iron; current density, 0.5 essays. It can be observed that, in both cases, precipitates are
mA cm-2; temperature, 25 °C; flowrate, 50 dm3 h-1; initial pH, 4.5; kaolin the primary species. In the electrocoagulation with aluminum,
concentration, 1000 mg dm-3; supporting media, 3000 mg dm-3 of NaCl; a significant concentration of monomeric ions are observed,
volume, 1.5 dm-3. (c) s, isoelectric point. while in the case of iron, the concentrations are completely
negligible. Taking into account this speciation and also the
results obtained in the electrocoagulation of kaolin suspensions.
values of the zeta potential, it can be suggested that sweep
Great differences are observed in the turbidity changes with the
coagulation is the primary mechanism in the coagulation with
dose of coagulant reagents. In the case of aluminum, two zones
iron. In the coagulation with aluminum, two unconnected
of high efficiency can be clearly discerned: one for low
mechanisms operate: for low concentration, the primary mech-
aluminum doses (range 0.05-0.15 mmol dm-3) and another
anism is charge neutralization by monomeric cationic aluminum
for high aluminum concentration (range > 0.6 mmol dm-3).
species, while for high doses, sweep coagulation with amorphous
Both zones are clearly split by a minimum in the turbidity
aluminum hydroxide explains the results.
removal (∼0.35 mmol dm-3). On the contrary, the coagulation
with iron does not exhibit this minimum and only one high- Electrocoagulation of a Wastewater Polluted with EBT.
efficiency coagulation zone is observed. The pH increases in Figures 6 and 7 show the results obtained in the electrocoagu-
both cases up to a value of 7. In the case of iron, the change is lation of wastewaters polluted with EBT, using aluminum or
very abrupt, while in the case of aluminum, there is a softer iron as electrode materials.
increase. The major differences are observed for the zeta A similar behavior is obtained for both electrodic materials,
potential. As can be seen in the case of aluminum electroco- although the doses required to meet the same efficiencies are
agulation, a zeta potential of zero is achieved close to the lower in the case of aluminum and, in addition, the removal
concentration of aluminum in which the maximum of turbidity efficiencies are slightly higher for this material (very close to
removal is obtained. In the case of iron electrocoagulation, the 100%). Measured pHs and zeta potentials increase during the
zeta potential is always negative except for the very high dosage treatment, and the values of the zeta potential are always
in which it is close to zero. negative. Significant concentrations of monomeric and poly-
These observations have to be explained in terms of the meric ions are measured during the aluminum dosage, while
aluminum or iron species formed in the reaction system. In this the iron dosage does not exhibit the formation of these species.
context, it is important to take into account that the aqueous Taking into account these observations, the binding of EBT
chemistry of aluminum and iron is especially complex, as it molecules to the surface of small iron or aluminum precipitated
involves not only monomeric ionic species and the formation particles can be suggested as the primary mechanism. These
of precipitates but also oligomeric and polymeric species. precipitate particles can adsorb both the EBT molecules and
Ind. Eng. Chem. Res., Vol. 46, No. 19, 2007 6193

Figure 6. Removal of EBT, pH, and zeta potential for an electrocoagulation


assay of a wastewater polluted with EBT in batch-operation mode using as
electrode material: [, aluminum; 0, iron; current density, 1.4 mA cm-2; Figure 8. Removal of COD, pH, and zeta potential for an electrocoagulation
temperature, 25 °C; flowrate, 50 dm3 h-1; initial pH, 4; EBT concentration, assay of an O/W emulsion in batch operation mode using as electrode
100 mg dm-3; supporting media, 3000 mg dm-3 of NaCl; volume, 1.5 dm-3. material: [, aluminum; 0, iron; current density, 2.2 mA cm-2; temperature,
(c) s, isoelectric point. 25 °C; flowrate, 50 dm3 h-1; initial pH, 8.5; oil concentration, 3000 mg
dm-3; supporting media, 3000 mg dm-3 of NaCl; volume, 1.5 dm-3. (c)
s, isoelectric point.

by electrostatic attraction between the negative functional groups


of EBT and the positive adsorption sites of the precipitate. In
the case of aluminum, the concentration of these ionic species
is very important, and this explains the high efficiency and also
the lower dose of coagulant needed. On the contrary, in the
case of iron, the prevalence of the precipitate over the ionic
species reduces the binding of the EBT molecules, resulting in
a lower efficiency process. In this context, it is important to
note that, although no soluble polymeric or monomeric iron
species are found (according to the ferron procedure), it does
not exclude that they could be directly adsorbed on the surface
of the amorphous iron hydroxide.
Electrocoagulation of an O/W Emulsion. Figure 8 shows
the main parameters involved in the electrochemical breakup
of an O/W emulsion using iron or aluminum electrodes (the
oily phase of the emulsion is composed by a common lubricant
oil (REPSOL ELITE TDI 15W40 provided by REPSOL-YPF,
Spain) and a soluble oil (SOL 1000 provided by Molydal,
France)). Likewise, Figure 9 shows the coagulant species in
Figure 7. Aluminum and iron speciation (expressed as aluminum and iron
concentration) in a batch operation mode electrocoagulation assay: -×-, both treatments determined according to the ferron procedure.
monomeric species; -9-, polymeric species; -[-, precipitate; current The influence of the dose of reagent on the treatment
density, 1.4 mA cm-2; temperature, 25 °C; flowrate, 50 dm3 h-1; initial efficiencies looks like that observed in the case of EBT
pH, 4; supporting media, 3000 mg dm-3 of NaCl; volume, 1.5 dm-3. electrocoagulation, although, in this case, the higher efficiencies
the coagulant ionic species. In the later case, this results in are obtained when iron is used as electrode material. The pH is
positive charge surfaces that can enhance the adsorption of EBT maintained almost constant during the treatments. On the
6194 Ind. Eng. Chem. Res., Vol. 46, No. 19, 2007

concentrations of monomeric and even (in some cases) poly-


meric ionic species.
• Sweep coagulation can explain the coagulation of kaolin
suspension with both aluminum and iron electrodes. However,
in the case of aluminum, the neutralization charge mechanism
should also be considered for low reagent doses.
• The binding of EBT to metal hydroxide precipitates can
explain the coagulation of this dye. This binding is promoted
for aluminum electrodes because of the adsorption of cationic
reagent species on the surface of the aluminum hydroxide. The
same mechanisms explain the breakup of O/W emulsions.

Acknowledgment
This work was supported by the MCT (Ministerio de Ciencia
y Tecnologı́a, Spain) and by the EU (European Union) through
Project CTM2004-03817/TECNO.

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