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Electrocoagulation Using Perforated Electrodes - PDF - Physical Sciences - Chemistry
Electrocoagulation Using Perforated Electrodes - PDF - Physical Sciences - Chemistry
Electrocoagulation Using Perforated Electrodes - PDF - Physical Sciences - Chemistry
% Electrocoagulation
fluid removal from using perforated electrodes: An increase in metalworking
wastewater
Oriane Avancini Diasa, Eduardo Perini Muniza,b, , Paulo Sérgio da Silva Portoa,c ⁎
Email a
Universidade Federal do Espírito Santo, Programa de Pós-graduaç ão em Energia, Rodovia Governador Mário Covas, km 60, Bairro Litorâneo, CEP 29932-540, S ão
Mateus, ES, Brazil
b
Universidade Federal do Espírito Santo, Departamento de Ciências Naturais, Rodovia Governador Mário Covas, Bairro Litorâneo, CEP 29932-540, S ão Mateus, ES, Brazil
c
Universidade Federal do Espírito Santo, Departamento de Engenharias e Tecnologia, Rodovia Governador Mário Covas, km 60, Bairro Litorâneo, CEP 29932-540, S ão
Mateus, ES, Brazil
Keywords: A continuous electrocoagulation reactor with electrode polarity switch was used for removal of a metalworking
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Effluent remediation fluid from synthetic oily water. The effects of perforating the aluminum electrodes, changing the number of
Electroflotation holes, flow rate and the distance between electrodes were studied. Higher values of flow rate reduced final pH.
Metalworking fluid Perforating the electrodes led to faster convergence of pH to its maximum value with no measurable increase in
Perforated electrodes
mass loss. If the distance between electrodes is also increased, there is an improvement in efficiency. With
Flow rate
10 holes, adjusting flow rate and inter-electrode distance, 90.2 ± 0.3% oil removal was achieved with a final pH
of 8.83, which is within limits allowed by legislation.
https://doi.org/10.1016/j.cep.2019.03.021
Received 29 November 2018; Received in revised form 27 March 2019; Accepted 31 March 2019
Available online 01 April 2019
0255-2701/ © 2019 Elsevier B.V. All rights reserved.
& Useful
O. Avancini Dias, et al. Chemical Engineering & Processing: Process Intensification 139 (2019) 113– 120
plane electrodes. They studied the effect of the number of holes in perforated and perforated plates, of same material and dimensions, to
aluminum electrodes in the color removal efficiency to remove acid 131 evaluate the effect of the presence of holes when the electrical current
dye from distilled water [15]. Efficiency increases with the number of modulus is kept constant. The position of the drilled holes in the per-
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holes from one to four and is not altered from four to eight holes. There Documents
forated plates is represented in Fig. 2. Holes with 6 mm diameter were
is no apparent change in efficiency with hole distribution. Removal drilled in symmetrical patterns around the center of the plates, to
efficiency increases with hole diameter from 2 to 4 mm but not from 4 guarantee a uniform flux of oily water, oxygen and hydrogen bubbles.
to 5 mm. The results were attributed to the higher current discharge The central hole and the hole at the top of the upper corner were filled,
from the punched electrode. used to realign the connection between the plates with the help of a
Hussin and co-workers [16] propose the use of perforated zinc threaded rod.
electrodes for lead (Pb) separation from water. Removal efficiency was A schematic drawing detailing the shape, layout, and assembly of
higher for perforated electrodes with a hole diameter of 0.5 cm than for the electrode plates is shown in Fig. 3. Two sets of three plates were
those with a hole diameter of 0.2 cm, and both were more efficient than aligned in the form of a beehive, each set interspersed and arranged in
the plane, non-perforated electrodes. The presence and size of the holes parallel (monopolar mode), the plates being separated by screws cov-
altered the electrical current between the electrodes and the authors ered with a polymer for electrical insulation.
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associated the higher efficiency with higher current density. Distances between electrodes (DE) were set as demanded by ex-
In the present work, electrical current was kept constant while the
distance between electrodes, the number of holes drilled on them and
flow rate were varied. The objective was to verify if other factors be-
$
perimental design (next section). From the literature, there is a ten-
dency of improvement in the process of separation of oil from water
when DE is increased from 5 to 10 mm in a reactor with polarity switch
sides current intensity or current density interfere in the change of ef- [17], justifying the use of 10 mm as a minimum value in the initial
2.3. EC procedure
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10 h from preparation. The solution was then kept at rest and watched
for 24 h to check for stability before EC was performed.
The values used for flow rate (Q), the number of holes (N) and the
distance between electrodes (DE) were as shown in Table 2. To de-
termine the experimental variables, initially a 2 3 factorial experimental
2.2. Electrocoagulation system design was used (experiments 1–8), then a central point was added in
triplicate (experiments 9, 10 and 11).
As described in a previous work [17], a monopolar arrangement of After the initial analysis, since it showed some improvement in ef-
three pairs of aluminum electrodes, polarity switch to preserve the ficacy with increasing N, it was decided to do a second set of experi-
electrodes and increase efficiency was used. Polarity reversal turns the ments with maximum N (fixed value), using a central composite design
cathode into anode and vice versa, which contributes to reducing the with Q and DE as variables (experiments 12,13 and 14). By design one
−1
passivation
electrode effect on the cathode and increases the lifespan of the
[17]. of the values
discarded sincetried
it isfor
tooQlow
should
to bebeof1.18 mL.min
practical butcentral
use. The this value
pointwas
of
While the modulus of the electrical current was kept constant at 4 A, this new set of experiments was made in triplicate (experiments 15, 16
polarity was changed each 30 s forming an input sign step function and 17). Once all was finished, the system with nonperforated elec-
(polarity reversal). Voltage modulus oscillated around 12 ± 3 V due to trodes had to be evaluated as a reference (experiments 18 and 19).
electrical resistance changes created by electrode passivation during the The electrical current tends to pass only in the metallic parts of the
process. The voltage switch time was adjusted for electrical stability, electrodes. If holes are drilled the area of the plates will be reduced and
resulting in a higher value than the 10 s found in the literature [ 17,19]. current density increased. The current density is estimated to be 493.83
The continuous flow EC pilot unit consisted of a rectangular elec- A. m−2 for a flat plate without the presence of holes. It grows to 508.01
trolytic cell, a set of aluminum electrodes, and an electronic device and 515.42 A. m−2 for 6 and 10 holes, respectively.
(plate) to switch the polarity of the current from a DC power source
(Fig. 1). The monopolar mode electrodes were connected to the polarity 2.4. Analytical methodology
switch and then to the DC power supply brand MINIPA model MPC-
3005. The characterization of the samples collected was carried out ac-
The electrodes are aluminum plates with the following dimensions: cording to methodologies adapted from the Standard Methods for the
130 mm height, 65 mm width and 0.50 mm thick, located vertically in Examination of Water and Wastewater [20].
the central part of the interior of the plexiglass reactor, whose electrical
wiring passes through holes located in the lid ( Fig. 1). The dimensions 2.5. Determination of pH
of the feed tank, reactor and receiver tank are shown in Table 1.
Tests were performed by measuring MCF removal efficacy with non- The pH of all samples was measured at 0, 5, 10, 20 and 30 min of
:
Tests were performed by measuring MCF removal efficacy with non- The pH of all samples was measured at 0, 5, 10, 20 and 30 min of
114
O. Avancini Dias, et al. Chemical Engineering & Processing: Process Intensification 139 (2019) 113– 120
Fig. 1. Schematic design of continuous flow electrolytic system. Where: (a) current power supply; (b) Polarity inverter; (c) Feed tank for raw fluent storage; (d)
submersible pump; (e) flow regulating valve; (f) electrode; (g) reactor input; (h) reactor output and (i) receiver tank for storing effluent after treatment.
Table 1 procedure were based on Method 4500 from the Standard Methods for
Dimensions of the EC apparatus. the Examination of Water and Wastewater [ 20].
Components of the system Dimensions Effective Volume
(cm) (mL)
2.6. Determination of electrical conductivity
Feed tank 33.0 × 22.0 × 22.0 15000
EC reactor (retangular) 30.2 × 1 5.2 × 1 5.0 3000
Receiver tank 25.2 ×18.0 ×18.0 8000 Electrical conductivity was obtained with the aid of the conductivity
meter BEL Engineering W12D, resolution of 0.1 μS. cm −1 and accuracy
of ± 1%. For each test the conductivity was verified, using a standard
electrocoagulation using a pH meter, Mark MS TECNOPON mPA210 NaCl solution of 1000 μS. cm−1. The calibration of the conductometer
with automatic temperature compensation, resolution 0.01 and accu- and the measurement procedure were based on Method 2510 from the
racy ± 0.01%. The calibration of the pH meter and the measurement Standard Methods for the Examination of Water and Wastewater [ 20].
Fig. 2. Aluminum plates used to compose the electrode: (a) perforated plates with 6 holes (b) perforated plates with 8 holes (c) plates with 10 holes.
115
O. Avancini Dias, et al. Chemical Engineering & Processing: Process Intensification 139 (2019) 113– 120
Fig. 3. Representation of the electrode assembly showing the mechanical connections between plates.
:
Table 2 function. From an analysis of the UV–vis spectra, the wavelength of
Operational conditions used for the experiments. 263 nm was ideal; a calibration curve was plotted and fit by a linear
Experiment N Q DE model (adjusted R-square of 0.9996), Eq. (1):
(mL.s−1) (mm)
OC (gL 1) = (336 ± 2)(gL 1)* Absorbance (1)
1 6 2 10
2 10 2 10 Where OC is oil concentration.
3 6 6 10 Oil removal efficacy of the process was evaluated by percent of oil
4 10 6 10
5 6 2 20 removal (OR%) as calculated using Eq. (2):
6 10 2 20
7 6 6 20 OC0 OCf
OR% = × 100
8
9 10
8 64 20
15 OCf (2)
10 8 4 15
11 8 4 15
where: OC0 is the initial oil concentration (time zero), OCf is the oil
12 10 6.8 15 concentration at the end of the process (30 min).
13 10 4 7.95
14 10 4 22.05
15 10 4 15 2.8. Determination of electrode consumption
16 10 4 15
17 10 4 15
18 0 2 10 The mass of the electrodes was measured before and after each
19 0 6 20 experiment to estimate the mass loss occurring during the process
(gravimetric measurement). Electrodes were washed and dried before
mass measurement to avoid the influence of eventual flakes or other
2.7. Determination of the content of oils and greases impurities attached during the EC process. The measurements were
carried out in an analytical balance Bioprecise brand FA-2104 N with a
A spectral method was used, based on method 5520 from the precision of 0.1 mg.
Standard Methods for the Examination of Water and Wastewater [ 20].
The oil was extracted from 50 mL samples using hexane as a solvent.
Then the UV–vis spectrum was measured, and the absorbance at a given 2.9. Microscopy
wavelength was used in a calibration curve to obtain oil concentration.
The spectrometer used was a QUIMIS 4802. Spectra were measured The surface of the electrodes was observed with an optical USB
from 190 to 700 nm with a precision of 1 nm. linked Microscope with magnification up to 1,000X, connected to a
The value of the wavelength was chosen as the one where the re- laptop. The microscope lens was placed about 10 mm above, perpen-
lation between concentration and absorbance was closer to a linear dicular to the plate and with the same illumination for all samples.
116
O. Avancini Dias, et al. Chemical Engineering & Processing: Process Intensification 139 (2019) 113– 120
2.10. Statistical analysis hydroxides that are responsible for oil removal.
The relation between k pH and the input variables will be discussed
To look for monotonic relations between input and output variables ahead, using Spearman correlation. For all experiments, adjusted R-
Spearman’s coefficient was calculated for the raw data using Origin ™ square is higher than 0.94, with pHf in the range from 8.60 to 9.75. As
software. Spearman’s is a non-parametric rank statistic that can be used listed in the methodology, the p-value test was considered statistically
as a measure of the strength of an association between two variables significant for p-value < 0.05.
[21] even when one of these variables is noncontinuous as is the case
for the number of holes drilled in a plate. The p-value test (p-value <
3.2. Variation of oil concentration with time
0.05 was considered statistically significant) was used to verify if a
Spearman correlation was significant. Only correlations that passed this
Typical results for variation of OR% with time are represented in
test are discussed in this work.
Fig. 5. All results could be adjusted, by non-linear fit, to an exponential
Since Spearman`s method finds only monotonic correlations, Q 2, N2,
model, with the form of Eq. (4):
DE2, N x Q, N x DE, Q x DE and Q x N x DE were used as variables to
k t
search
Thefor more complex
parameters of therelationships between
kinetic models input
for pH andand
OR% output
weredata.
esti-
OR% =
A (1 e OR ) (4)
mated by nonlinear regression using Origin ™ software. To evaluate the In this model, k OR (min−1) is the reaction rate of oil with aluminum
quality of fit, the adjusted R-square, the standard error, the p-value test hydroxide [17] and gives a measurement of reaction speed. The other
(p-value < 0.05 was considered statistically significant) and the F-test fitting parameter, A (%) is related to the amount of oil that might be
were used. All R-square were higher than 0.93. removed in an infinite time.
The fit parameters A and k OR are given in Table 4 together with the
3. Results and discussion final (t =30 min) percentage of oil removal (ORf). For all experiments,
the adjusted R-square of the exponential fit was higher than 0.93.
3.1. Variation of pH with time The exponential fit (Eq. (4)) is a characteristic equation for change
of concentration due to a pseudo-first-order chemical reaction. This
Typical results for pH variation with time are represented in Fig. 4. model is also used in the literature to describe EC, for the treatment of
The data can be fit by an exponential model (Eq. (3)) as described in a water contaminated with synthetic effluents of acid blue 113 dye [ 23]
previous work [17]: arsenic [24], phenol [25] and basic dye rhodamine [26]. The pseudo-
first-order behavior can be explained if the amount of aluminum hy-
pH = Y0 Be kpH t
(3) droxide is constant with time.
where: Y0 is the adjusted value for the final pH, B is a constant that
subtracted from Y0 gives the estimated initial value, k pH (min−1) is a 3.3. Electrical conductivity
reaction rate constant, a measurement of the number of dissolved ions
responsible for the rise in the pH value [ 17], t (min) is the time since the The electrical conductivity decreased by 0.9 ± 0.3 mScm −1 in all
beginning of the EC. experiments independent of the process variables (including the pre-
The variation of pH with time for the other experiments also can be sence of holes in electrodes). The average value of the conductivity
adjusted by Eq. (3), with the fit parameters shown in Table 3. Measured calculated for all experiments was 14.02 ± 0.07 mScm −1. Electrical
pH value at the end of the EC process ( pHf) is also displayed in the table. conductivity is related to the salinity of the medium, and the same
High kpH does not mean maximum pH f (Fig. 4), but a fast con- amount of NaCl was used in all experiments. The slight tendency of
vergence to a final value as happened in experiment 8 where pH sta- conductivity decrease may indicate a small reduction in salt con-
bilized after 10 min of treatment. It is usual for pH to rise during the EC centration with time.
process. One known reason for this behavior is the formation of an
excess of OH− on the cathode [22]. Excess meaning OH − that does not
combine with the Al+3 released by the anode to form the aluminum 3.4. Electrodes loss of mass
Percent loss of mass by the electrodes during the process was within
the range of 3.4 ± 0.8% for all experiments. These results agree with
Faraday`s equation, where the ratio of mass released to the fluid is
dependent on the electrical current modulus.
Loss of mass is a critical component of the cost associated with EC,
and it can be altered by other variables besides electrical current, in-
cluding DE [27] or possibly N. If it had increased with N, drilling holes
would not be an economically viable way of raising efficacy.
Despite the similar total loss of mass, the corrosion of the electrodes
took a different form for each experimental set. Optical micrography
with 1000x magnification shows that the diameter of the corrosion pits
(black areas in Fig. 6) and the apparent roughness of the plate increase
when 10 holes are used, with Q = 2 mLs −1 (Fig. 6A and B). The op-
posite happens when Q and DE are higher, and the electrode is perfo-
rated by 10 holes, there is a visible reduction in corrosion pit diameter
and in roughness (Fig. 6C and D).
The surface texture of the aluminum electrode is determinant in the
production of large bubbles in EC [ 28]. Rough surfaces may make it
more difficult for EC to generate small bubbles that tend to increase
separation efficiency. However, independent on the observed variations
Fig. 4. pH as a function of time. The lines represent the exponential fit as de- in roughness or pit diameter, OR f increased when holes were drilled if
scribed in the text. ■ = experiment 3, = experiment 6, experiment 8. the other variables were kept constant.
117
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O. Avancini Dias, et al. Chemical Engineering & Processing: Process Intensification 139 (2019) 113– 120
Table 3
Fit parameters that describe the variation of pH with time.
Exp. Value Standard Error Value Standard Error Value Standard Error
Table 4
Parameters that describe the variation of oil removal with time.
Spearman's
given correlation coefficients between the variables have been
in Table 5. equal±to0.3%,
90.2 4 mL.s the value
independent of N of ORf was practically constant at
x DE.
N has a significant positive correlation with kpH (Table 5). Since kpH For Q of 2 mL.s−1, ORf has a linear relationship with N x DE ( Fig. 7).
may be associated with the excess of OH − [22,17], drilling holes may While for Q of 6 mL.s−1 a linear fit of ORf with N x DE is possible, with
be helping in the production of this ion. Possible reasons are the in- an exception for the non-perforated electrode. Nonetheless, Fig. 7
crease in electrical current density and the flux of gas through the holes. shows a tendency of growth in OR f if holes are made in non-perforated
Q has a significant negative correlation with pHf and ORf, as ex- electrodes.
pected. With higher Q, the molecules of the fluid have less time to in- For any value of Q, if DE is kept constant and N is increased, there is
teract with the aluminum, resulting in smaller total variation in pH. The a tendency of growth in ORf, but if DE is reduced and N increased, ORf
positive correlation with kOR shows that the faster removal of ions of will be reduced. The ideal behavior to improve process efficacy is to
the electrode surfaces with higher Q leads to an increase in corrosion, as compensate the turbulence created by drilling holes in the electrode by
was observed by Krystynik and Tito [ 29]. increasing DE.
DE does not have a significant correlation with any other variable, The question posed in this work is answered, if increasing current
and this is unusual in EC; thus quadratic correlations were searched. density were enough to improve efficacy, N would interfere in OR f in-
Spearman`s correlations were calculated with Q 2, N2, DE2, N x Q, N x dependent of DE. Since the improvement depends on a combination of
DE, Q x DE and Q x N x DE as variables. The only combination that the two variables, it must be related to the passage of fluid through the
resulted in correlations not seen for the component variables was be- holes.
tween N x DE and ORf. The change in ORf when N x DE increases for Q Power consumption (related to electrical current modulus) and
118
O. Avancini Dias, et al. Chemical Engineering & Processing: Process Intensification 139 (2019) 113– 120
:
Fig. 6. Optical micrographs of the electrode plates after EC. A – Experiment 18 (N= 0, DE = 10, Q = 2), B- Experiment 2 (N= 10, DE= 10, Q = 2), C- Experiment
19 (N = 0, DE = 20, Q = 6), D - Experiment 8 (N = 10, DE= 20, Q = 6).
4. Conclusions
N 0.3652 0.1242 0.0822 0.7379 −0.1855 0.4470 0.6213 0.0045 0.1921 0.4307
Q −0.5640 0.0119 0.9441 < 0.0001 −0.9082 < 0.0001 0.0660 0.7884 −0.2723 0.2595
DE 0.2530 0.2960 0.1485 0.5440 0.0550 0.8230 −0.0880 0.7202 −0.0715 0.7712
N x DE 0.5059 0.0271 0.0428 0.8621 −0.0116 0.9625 0.3776 0.1110 0.2414 0.3195
Where: Sc means Spearman coefficient, N is the number of holes, Q is flow rate, DE distance between electrodes. A two-tailed test of significance was used, bold
values indicate significant correlations (p-value < 0.05).
119
O. Avancini Dias, et al. Chemical Engineering & Processing: Process Intensification 139 (2019) 113– 120
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