A system for removing metal ions from wastewater by electrocoagulation

Abstract

A system for removing metal ions from wastewater by electrocoagulation, comprising: an electrocoagulation reactor consisting of a plastic container configured to receive wastewater containing aluminum and iron ions; a plurality of aluminum electrodes arranged in a monopolar configuration within the electrocoagulation reactor with a fixed distance between adjacent electrodes; a DC power supply configured to supply an adjustable voltage to the plurality of aluminum electrodes; a pH adjustment unit configured to maintain the wastewater at a predetermined pH value; and a control unit configured to: Monitoring and control of the DC power supply; Maintaining a constant current during the electrocoagulation process; regulate the duration of treatment; and Check sampling intervals during the treatment process.

Description

FIELD OF THE INVENTION

[0001] The present disclosure relates to a system for removing metal ions from wastewater using electrocoagulation. More specifically, the present invention relates to a system for removing Al and Fe from synthetic wastewater using electrocoagulation. The system utilizes multiple aluminum electrodes to separate metal ions from the wastewater. BACKGROUND OF THE INVENTION

[0002] Rapid industrialization and growing environmental concerns make wastewater treatment a major challenge, especially for wastewater containing heavy metals. Conventional treatment methods often prove costly, inefficient, or environmentally harmful due to the generation of secondary waste. Electrocoagulation has proven to be a promising solution, but existing systems reach their limits when it comes to treating high concentrations of specific metal ions, particularly aluminum and iron, which are commonly found in industrial wastewater.

[0003] This invention addresses these challenges with a novel electrocoagulation system specifically designed for the efficient removal of aluminum and iron ions from wastewater. The system utilizes precisely configured aluminum electrodes in a monopolar array, combined with controlled pH conditions and optimized treatment times. Unlike conventional systems, this invention enables real-time monitoring and precise control of treatment parameters. This enables higher removal efficiencies while maintaining cost effectiveness. Summary of the invention

[0004] The present disclosure relates to a system for removing metal ions from wastewater using electrocoagulation. The proposed system efficiently removes aluminum and iron ions from wastewater by utilizing precisely configured aluminum electrodes in a monopolar arrangement, controlled pH conditions, and an optimized treatment time. The unique design of the system enables the treatment of wastewater with metal ion concentrations of 100 to 300 mg / L, thus closing a significant gap in current treatment options. By carefully optimizing the electrode configuration, pH, and treatment time, the invention achieves higher removal efficiency than conventional electrocoagulation systems.

[0005] The present disclosure aims to provide a system for removing metal ions from wastewater by electrocoagulation. The system comprises: an electrocoagulation reactor with a plastic container for receiving wastewater containing aluminum and iron ions; a plurality of monopolar aluminum electrodes arranged in the electrocoagulation reactor with a fixed electrode spacing; a DC power supply for supplying the aluminum electrodes with adjustable voltage; a pH control unit for maintaining a predetermined pH value of the wastewater; and a control unit for monitoring and controlling the DC power supply, maintaining a constant current of 1.5 A during electrocoagulation, regulating the treatment duration, and controlling the sampling intervals.

[0006] An object of the present disclosure is to provide a system for removing metal ions from wastewater by electrocoagulation.

[0007] Another object of the present disclosure is to provide a wastewater treatment system for removing aluminum and iron ions using aluminum electrodes.

[0008] Another object of the present disclosure is to provide a system that facilitates the evaluation of the effects of treatment time, pH, and initial ion concentration on the removal efficiency of aluminum and iron ions, wherein the treated samples are collected to measure the residual concentration of the target ions.

[0009] To further clarify the advantages and features of the present disclosure, the invention will be explained in more detail with reference to specific embodiments illustrated in the accompanying drawings. These drawings illustrate only typical embodiments of the invention and are therefore not to be considered as limiting its scope. The invention will be described and explained in more detail with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE CHARACTERS

[0010] These and other features, aspects, and advantages of the present disclosure will become more fully understood when the following detailed description is read with reference to the accompanying drawings, in which like characters represent like parts throughout. Fig. 1 shows a block diagram of a system for removing metal ions from wastewater using electrocoagulation according to an embodiment of the present disclosure; Fig. 2A and Fig. 2B illustrate diagrams of the electrode and reactor tank according to an embodiment of the present disclosure; Fig. 3 is a schematic diagram illustrating the operational connection between the power supply and the reactor tank of the system according to an embodiment of the present disclosure; and Fig. 4 shows a block diagram of the present invention according to an embodiment of the present disclosure.

[0011] Those skilled in the art will also appreciate that the elements in the drawings are shown for convenience and are not necessarily to scale. For example, the flowcharts illustrate the method by key steps to enhance understanding of aspects of the present disclosure. Furthermore, with respect to device construction, one or more components of the device may be represented in the drawings by conventional symbols. The drawings may show only the specific details relevant to understanding embodiments of the present disclosure in order not to clutter the drawings with details that would be readily apparent to those skilled in the art from the present description. DETAILED DESCRIPTION:

[0012] To facilitate an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and a clear description thereof. However, the scope of the invention is not limited thereby. Changes and further modifications to the illustrated system, as well as further applications of the principles of the invention, are possible, as would normally occur to one skilled in the art to which the invention pertains.

[0013] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.

[0014] References in this specification to "one aspect," "another aspect," or similar language mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Therefore, the language "in one embodiment," "in another embodiment," and similar language throughout this specification may or may not refer to the same embodiment.

[0015] The terms "comprises," "comprising," or variations thereof are intended to be non-exclusive inclusion. A process or method that includes a list of steps includes not only those steps, but may also include additional steps not expressly listed or inherent in the process or method. Likewise, the statement "comprises" for one or more devices, subsystems, elements, structures, or components does not exclude, without further limitation, the existence of other devices, subsystems, elements, structures, or components, or of additional devices, subsystems, elements, structures, or components.

[0016] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. The systems, methods, and examples provided herein are for illustrative purposes only and should not be considered limiting.

[0017] Embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings.

[0018] Fig. 1 shows a block diagram of a system (100) for removing metal ions from wastewater using electrocoagulation according to an embodiment of the present disclosure.

[0019] According to Fig. 1, the system (100) comprises: an electrocoagulation reactor (102) having a plastic container (102a) for receiving wastewater containing aluminum and iron ions; a plurality of aluminum electrodes (104) arranged in a monopolar configuration within the electrocoagulation reactor (102) with a fixed distance between adjacent electrodes; a DC power supply (106) for supplying the plurality of aluminum electrodes (104) with adjustable voltage; a pH adjustment unit (108) for maintaining a predetermined pH value of the wastewater; and a control unit (110) for monitoring and controlling the DC power supply; maintaining a constant current of 1.5 A during the electrocoagulation process; regulating the treatment duration; and controlling the sampling intervals during the treatment process.

[0020] In one embodiment, the electrocoagulation reactor (102) comprises a plastic container (102a) having dimensions of 16 centimeters in length, 16 centimeters in width, and 18 centimeters in height, wherein the plastic container (102a) is configured to process 3 liters of wastewater in a single treatment cycle.

[0021] In one embodiment, each aluminum electrode of the plurality of aluminum electrodes (104) has a height of 8 centimeters, a width of 14 centimeters, and a thickness of 1 millimeter, wherein the fixed distance between adjacent electrodes is 15 millimeters.

[0022] In one embodiment, the DC power supply (106) is configured to provide a voltage in the range of 0 to 30 volts, maintain a constant current of 1.5 A throughout the treatment process, and allow adjustable current settings based on treatment requirements.

[0023] In one embodiment, the pH adjustment unit (108) comprises: storage tanks for acid and base solutions; a pH monitoring device (108a); dosing pumps for acid and base solutions; and a control mechanism (108b) configured to maintain the pH of the wastewater at predetermined values ​​of 4, 6, or 8.

[0024] In one embodiment, the control unit (110) is further configured to monitor the removal efficiency of aluminum and iron ions, calculate metal ion concentrations at different time intervals, generate removal efficiency data, and adjust treatment parameters based on the monitored efficiency.

[0025] In one embodiment, the system (100) further comprises a mixing mechanism (112) configured to provide gentle agitation during the electrocoagulation process, prevent floc settling, and ensure even distribution of the electrical current throughout the wastewater.

[0026] In one embodiment, the system (100) further comprises a power monitoring system (114) configured to measure voltage and current in real time, calculate power consumption, and optimize energy consumption during the treatment process.

[0027] In one embodiment, the system (100) is configured to treat wastewater containing aluminum ion concentrations in the range of 100 to 300 milligrams per liter and iron ion concentrations in the range of 100 to 300 milligrams per liter.

[0028] The present invention relates to a system for removing metal ions from wastewater using electrocoagulation. The proposed system operates in a precisely designed plastic reactor measuring 16 × 16 × 18 centimeters and can treat three liters of wastewater per cycle. The system uses monopolar aluminum electrodes, each 8 centimeters high, 14 centimeters wide, and 1 millimeter thick. The electrode spacing is 15 millimeters. A DC power supply delivers an adjustable voltage of 0 to 30 volts and ensures a constant current of 1.5 amperes throughout the entire treatment process. The system incorporates a sophisticated pH control unit that precisely regulates the pH of the wastewater to 4, 6, or 8 through automated dosing of acid and base solutions.During operation, the control unit continuously monitors treatment parameters and regulates the process. A sampling system takes 50-milliliter samples at 15-minute intervals for up to 60 minutes. A gentle mixing mechanism prevents floc buildup and ensures an even current distribution in the wastewater. The performance monitoring system optimizes energy consumption by measuring voltage and current in real time, while simultaneously calculating the removal efficiency for aluminum and iron ions at concentrations ranging from 100 to 300 milligrams per liter. This integrated approach enables efficient treatment of metal-laden wastewater while maintaining precise control of all operating parameters.

[0029] Fig. 2A and Fig. 2B illustrate diagrams of the electrode and reactor tank according to an embodiment of the present disclosure.

[0030] The components of the proposed electrocoagulation-based system include electrodes, a power supply, a reactor or tank, wastewater samples, sample bottles, and pH-adjustment chemicals. The electrodes serve as a coagulant source, while the sacrificial anode, typically made of aluminum or iron, dissolves upon application of an electric current, releasing metal ions that destabilize the contaminants in the water. At the same time, the cathode generates hydrogen gas, which aids flotation and thus facilitates the collection and removal of contaminants. As described in Fig. As shown in Figure 2A, the sacrificial electrodes used are aluminum plates measuring 8 cm high, 14 cm wide, and 1 mm thick. The power supply provides the necessary electrical current to drive the electrochemical reactions, ensuring the dissolution of the sacrificial anode and the generation of hydrogen gas at the cathode. To maintain process efficiency, a direct current (DC) source with adjustable voltage and current settings is used. The reactor or tank acts as a containment system in which the water treatment takes place. It houses the electrodes and ensures proper contact between the contaminated water and the generated coagulants. It facilitates the destabilization, aggregation, and removal of contaminants while providing space for sedimentation, flotation, or further separation processes. Fig. 2B, the electrocoagulation cell consists of a thick plastic container measuring 16 cm × 16 cm × 18 cm. The wastewater sample represents the contaminated water undergoing treatment and allows for an evaluation of the process's effectiveness by providing the medium for electrochemical reactions. Analysis of sample properties such as pH, conductivity, and contaminant types helps optimize treatment parameters for efficient contaminant removal and improved water quality. These samples can be synthetic or real wastewater containing specific contaminants such as heavy metals, dyes, or organic compounds. Small sampling bottles are used to collect samples of the treated water at varying intervals for further analysis.In addition, pH adjustment chemicals, including acids such as hydrochloric acid and bases such as sodium hydroxide, are used to optimize the pH and ensure that the electrocoagulation process works effectively.

[0031] Fig. 3 is a schematic diagram showing the operational power supply to reactor tank connection of the system according to an embodiment of the present disclosure.

[0032] According to Fig. 3, the electrocoagulation cell was made from a thick plastic container measuring 16 cm × 16 cm × 18 cm. The experimental equipment is in Fig. schematically shown. The total volume of wastewater sampled in each experiment was 31. The sacrificial electrodes used were 8 cm high, 14 cm wide, and 1 mm thick aluminum plates arranged in a monopolar configuration. Six plates were constructed in the electrochemical reactor with a fixed spacing of 15 mm between the plates. A constant current was maintained using a DC power supply with a current range of 0 to 30 V and 1.5 A.

[0033] Fig. 4 shows a block diagram of the present invention according to an embodiment of the present disclosure.

[0034] Referring to Fig.4. The electrocoagulation system for ion removal consists of various components that work together to ensure efficient treatment of synthetic wastewater containing aluminum and iron ions. The system focuses on key chemical inputs such as aluminum nitrate (Al(NO 3 ) 3 ), iron nitrate (Fe(NO 3 ) 3), deionized water, and pH-adjusting solutions such as hydrochloric acid (HCl) and sodium hydroxide (NaOH). These chemicals interact in a controlled electrochemical environment to facilitate coagulation and subsequent removal of the target ions. The operating framework is supported by specialized equipment, including an electrocoagulation setup with a 3-liter treatment tank, aluminum electrodes, and a DC power supply. Additional instrumentation such as a pH meter, 50-mL sample bottles, pipettes, and laboratory-based analytical tools such as atomic absorption spectrophotometry (AAS) or inductively coupled plasma-mass spectrometry (ICP-MS) ensure precise monitoring and evaluation of ion concentration dynamics throughout the process.

[0035] The core of the system's functionality is the treatment of synthetic wastewater, which is structured to contain three different sets of 3-liter samples containing aluminum nitrate and iron nitrate at concentrations of 100 mg / L, 200 mg / L, and 300 mg / L. The quantitative determination of aluminum and iron nitrate is performed according to a rigorous calculation process based on their respective molar masses, ensuring accurate solution preparation. To achieve an aluminum concentration of 100 mg / L, approximately 0.79 grams of Al(NO 3 ) 3 in one liter of water. Similarly, for iron nitrate, a concentration of 100 mg / l of iron is achieved by dissolving 0.43 grams of Fe(NO 3 ) 3in one liter of water. The pH of each prepared sample is adjusted to values ​​of 4, 6, and 8 using HCl and NaOH solutions. A calibrated pH meter is used to confirm and maintain the accuracy of the pH adjustment.

[0036] The electrocoagulation process is carried out in a structurally optimized tank measuring 16 cm × 16 cm × 18 cm to ensure contamination-free operation. Aluminum electrodes measuring 8 cm × 14 cm × 1 mm are arranged in parallel within the tank to ensure uniform current distribution and effective interaction with the wastewater matrix. These electrodes are connected to a DC power supply and provide a controlled and stable electrical input voltage—a critical factor in maintaining the ion removal mechanism. Once a 3-liter wastewater sample is added to the tank, the system is activated by switching on the power supply, initiating the electrocoagulation process.During this phase, 50 ml samples are systematically taken at 15-minute intervals—specifically, after 15, 30, 45, and 60 minutes—to ensure time-dependent monitoring of ion removal efficiency. Each sample is carefully labeled to reflect the experimental conditions, including the initial ion concentration and pH. The system ensures homogeneity in the treatment environment through gentle stirring, thus preventing premature settling of flocs and improving reaction uniformity.

[0037] Following electrocoagulation, the collected samples are processed in a laboratory, where suspended solids and flocculants are removed by filtration before a detailed ion concentration analysis is performed. Using advanced analytical techniques, including atomic absorption spectrophotometry (AAS) and inductively coupled plasma mass spectrometry (ICP-MS), the remaining concentrations of aluminum and iron ions in each sample are determined. The system integrates a robust data acquisition and analysis framework to quantify ion removal efficiency, which is determined using the following formula: Removal efficiency (%) = (Cinitial - Cfinal) / Cinitial × 100, where Cinitial and Cfinal represent the initial and final ion concentrations, respectively.Time-based performance metrics are also examined by plotting ion concentration trends across different pH values ​​and initial nitrate concentrations against electrocoagulation duration. These evaluations provide important insights into the system's operating efficiency and ultimately determine optimal treatment conditions, including the ideal pH, nitrate concentration, and reaction time, to maximize aluminum and iron ion removal.

[0038] The present invention relates to an advanced electrocoagulation-based system for the efficient removal of aluminum and iron ions from synthetic wastewater using aluminum electrodes. The system consists of a batch electrocoagulation unit operating in a controlled environment. Wastewater samples are treated there to optimize the removal of metal ions.

[0039] Synthetic wastewater was prepared by dissolving aluminum nitrate and iron nitrate at concentrations of 100 mg / L, 200 mg / L, and 300 mg / L at pH values ​​of 4, 6, and 8, respectively. This resulted in nine different solutions, each containing 3 liters of wastewater. The system uses a 3-liter reaction tank in which each solution is individually subjected to electrocoagulation. Samples are taken at 15-minute intervals for up to 60 minutes for subsequent laboratory analysis.

[0040] The main objectives of this system are to develop a batch electrocoagulation arrangement using aluminum electrodes for the treatment of synthetic wastewater, achieve extensive removal of Fe and Al metal ions, measure the ion concentrations after treatment, and determine the maximum removal efficiency under different conditions.

[0041] Experimental observations show that the system exhibits high metal ion removal efficiency at different pH values ​​and treatment times. For aluminum, the highest removal efficiency of 81.78% was recorded within 15 minutes at a pH of 4 and an initial concentration of 100 mg / L, which can be attributed to the rapid formation of aluminum hydroxide flocs. At a pH of 6, the system achieved an efficiency of 88.45% for 200 mg / L within 30 minutes, which can be attributed to optimal contaminant adsorption and floc formation. However, at a pH of 8, aluminum removal reached a peak of 56.46% within 15 minutes due to initially efficient flocculation, followed by destabilization over time.

[0042] The system demonstrated even greater effectiveness for iron: thanks to optimal flocculation and precipitation, a maximum iron removal of 96.77% for 200 mg / l was achieved after 45 minutes at a pH of 4. At a pH of 6, iron removal reached 98.48% after 60 minutes for 300 mg / l, due to prolonged electrolysis that promoted floc aggregation. A similar result was achieved at a pH of 8: a removal of 97.78% for 100 mg / l was achieved after 60 minutes, as the prolonged reaction time facilitated electrochemical precipitation.

[0043] Additionally, the system's impact on electrode integrity was analyzed. This revealed a cathode weight reduction due to mechanical wear and localized corrosion. Cathode 1 weighed less than 28.57 g to 27.717 g, cathode 2 weighed less than 28.49 g to 27.642 g, and cathode 3 weighed less than 28.59 g to 20.819 g. This weight reduction is primarily due to hydrogen evolution, mechanical erosion, and interactions with the electrolyte, particularly at extreme pH values. In contrast to conventional coagulation systems, this electrocoagulation-based approach significantly reduces the formation of chemical sludge and improves ion removal efficiency without excessive reagent consumption. The system's controlled electrochemical reactions result in more sustainable and cost-effective wastewater treatment.

[0044] In summary, this system represents a significant improvement over conventional wastewater treatment processes, achieving high removal efficiencies for aluminum and iron ions, minimizing secondary pollution, and reducing chemical consumption. Observations confirm that the effectiveness of the system is highly dependent on pH, initial metal ion concentration, and treatment duration, with optimal results achieved under specific conditions. This invention provides an environmentally friendly and efficient solution for industrial wastewater treatment and offers superior performance compared to conventional coagulation processes.

[0045] The drawings and the foregoing description illustrate examples of embodiments. Those skilled in the art will recognize that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be separated into multiple functional elements. Elements of one embodiment may be added to another embodiment. For example, the order of the processes described herein may be changed and is not limited to the manner described herein. Furthermore, the actions of a flowchart need not be performed in the order shown; nor do all actions need to be performed. Also, actions that are not dependent on other actions may be performed in parallel with the other actions. The scope of the embodiments is in no way limited by these specific examples.Numerous variations, whether explicitly stated in the specification or not, such as differences in structure, dimensions, and use of materials, are possible. The scope of the embodiments is at least as broad as indicated in the following claims.

[0046] Advantages, further benefits, and solutions to problems have been described above with reference to specific embodiments. However, the advantages, advantages, solutions to problems, and any components that may result in or enhance an advantage, benefit, or solution are not to be construed as critical, required, or essential features or components of any or all of the claims. REFERENCES 100 A system for removing metal ions from wastewater by electrocoagulation. 102 electrocoagulation reactor 102a Plastic containers 104 variety of aluminum electrodes 106 DC power supply 108 pH adjustment unit 108a pH monitor 108b Control mechanism 110 Control unit 112 Mixing mechanism 114 Performance Monitoring System 302 DC power supply 304 Reactor 306 aluminum electrodes 402 Study on Electrocoagulation 404 Material collection 406 Tank 408 electrodes 410 DC power supply 412 Chemical Required 414 Conducting the test 416 Sampling 418 Iron concentration 420 aluminum concentration 422 Results Analysis and Discussion

Claims

[1] A system for removing metal ions from wastewater by electrocoagulation, comprising: an electrocoagulation reactor consisting of a plastic container configured to receive wastewater containing aluminum and iron ions; a plurality of aluminum electrodes arranged in a monopolar configuration within the electrocoagulation reactor with a fixed distance between adjacent electrodes; a DC power supply configured to supply an adjustable voltage to the plurality of aluminum electrodes; a pH adjustment unit configured to maintain the wastewater at a predetermined pH value; and a control unit configured to: Monitoring and control of the DC power supply; Maintaining a constant current during the electrocoagulation process; regulate the duration of treatment; and Check sampling intervals during the treatment process. [2] The system of claim 1, wherein the electrocoagulation reactor comprises a plastic container having dimensions of 16 centimeters long, 16 centimeters wide, and 18 centimeters high, the plastic container being configured to process 3 liters of wastewater in a single treatment cycle. [3] The system of claim 1, wherein each aluminum electrode of the plurality of aluminum electrodes has a height of 8 centimeters, a width of 14 centimeters, and a thickness of 1 millimeter, wherein the fixed distance between adjacent electrodes is 15 millimeters. [4] The system of claim 1, wherein the DC power supply is configured to provide a voltage in the range of 0 to 30 volts, maintain a constant current of 1.5 A throughout the treatment process, and allow adjustable current settings based on treatment requirements. [5] The system of claim 1, wherein the pH adjustment unit comprises: Storage tanks for acid and base solutions; a pH monitoring device; dosing pumps for acid and base solutions; and a control mechanism configured to maintain the pH of the wastewater at predetermined values of 4, 6, or 8. [6] The system of claim 1, wherein the control unit is further configured to monitor the removal efficiency of aluminum and iron ions, calculate metal ion concentrations at different time intervals, generate removal efficiency data, and adjust the treatment parameters based on the monitored efficiency. [7] The system of claim 1, further comprising a mixing mechanism configured to provide gentle agitation during the electrocoagulation process, prevent floc settling, and ensure even distribution of the electrical current throughout the wastewater. [8] The system of claim 1, further comprising a power monitoring system configured to measure voltage and current in real time, calculate power consumption, and optimize power consumption during the treatment process. [9] The system of claim 1, wherein the system is configured to treat wastewater containing aluminum ion concentrations in the range of 100 to 300 milligrams per liter and iron ion concentrations in the range of 100 to 300 milligrams per liter.

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