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Chemical Engineering Journal 292 (2016) 308–314

Contents lists available at ScienceDirect

Chemical Engineering Journal


journal homepage: www.elsevier.com/locate/cej

Energy efficient electrocoagulation using an air-breathing cathode


to remove nutrients from wastewater
Yushi Tian a, Weihua He a, Xiuping Zhu b, Wulin Yang b, Nanqi Ren a,⇑, Bruce E. Logan a,b,⇑
a
State Key Laboratory of Urban Water Resource and Environment, Harbin Institute of Technology, No. 73 Huanghe Road, Nangang District, Harbin 150090, PR China
b
Department of Civil & Environmental Engineering, Penn State University, 231Q Sackett Building, University Park, PA 16802, USA

h i g h l i g h t s

 First application of an air-breathing cathode for electrocoagulation (EC).


 Energy reduced for treatment due to lack of a need for wastewater aeration.
 High efficiency in the removal of nutrients from wastewater.
 Design allows for a compact, stackable and modular configuration.

a r t i c l e i n f o a b s t r a c t

Article history: Electrocoagulation (EC) can be used to remove nutrients as well as suspended solids and organic carbon
Received 12 December 2015 from wastewaters, but the high energy requirements (pumping air) and the use of precious metals in
Received in revised form 30 January 2016 some processes has hindered widespread application of EC technologies. The use of a thermodynamically
Accepted 1 February 2016
favorable activated carbon air cathode and a sacrificial aluminum anode was examined to reduce the
Available online 5 February 2016
energy needed for EC for nutrient removal. Performance of the air cathode electrocoagulation (ACEC) pro-
cess was tested using raw wastewater, and a carbon-free synthetic solution (nitrogen:phosphorus ratio of
Keywords:
1:10 in deionized water) to simulate nutrient removal of a wastewater treated for organic matter
Energy efficiency
Wastewater treatment
removal. ACEC treatment of wastewater removed up to 99% of both ammonia and phosphorus, along with
Electrocoagulation 72–81% COD and 78–89% TSS in 4 h (1.5 cm electrode spacing, current density of 8 A m2). Nearly total
Air-cathode removal of the nutrients required 1.8 kWh m3, which is lower than that previously reported for some
Aluminum electrode EC processes for this application (0.4–22 kWh m3). Nutrient removals using synthetic solutions (no
organic matter) ranged from 74% to 93% for nitrogen (47–370 mg-N/L) and 44–76% for phosphorus.
These results indicate that the ACEC can achieve good levels of nutrient removal with reduced energy
demands compared to previous EC systems.
Ó 2016 Elsevier B.V. All rights reserved.

1. Introduction processes that can be coupled to these anaerobic systems are


needed in order to achieve nutrient removal [5].
In recent years, there has been great interest in the develop- Electrocoagulation (EC) is an electrochemical process that can
ment of completely anaerobic treatment processes, such as anaer- be used to treat wastewaters in terms of both organic matter and
obic fluidized bed reactors, anaerobic membrane bioreactors [1–3] nutrient removal [6,7]. The process is based on the use of sacrificial
and microbial fuel cells (MFCs) [4]. While these processes can be electrodes such as aluminum, iron, and zinc [8–11] that are oxi-
used to remove organic matter, there is little nutrient (nitrogen dized to produce metal ions that can be used to coagulate and react
and phosphorus) removal in these processes. Therefore, effective with organic matter and nutrients in the wastewater. When cur-
rent is applied, the metal ions that are produced react with primary
hydroxides and produce polyhyroxides and polyhydroxy-metallic
⇑ Corresponding authors at: Department of Civil & Environmental Engineering, flocs [12]. When aluminum is used as the sacrificial electrode
Penn State University, 231Q Sackett Building, University Park, PA 16802, USA. Tel.: material, the primary chemical species that are produced under
+1 814 863 7908; fax: +1 814 863 7304 (B.E. Logan). State Key Laboratory of Urban typical alkaline (pH of 7.5–9) or acidic (pH 3.5–6) conditions at
Water Resource and Environment, Harbin Institute of Technology, No. 73 Huanghe
the anode (20 °C) are:
Road, Nangang District, Harbin 150090, PR China. Tel.: +86 13904651427 (N. Ren).
E-mail addresses: rnq@hit.edu.cn (N. Ren), blogan@psu.edu (B.E. Logan).

http://dx.doi.org/10.1016/j.cej.2016.02.004
1385-8947/Ó 2016 Elsevier B.V. All rights reserved.
Y. Tian et al. / Chemical Engineering Journal 292 (2016) 308–314 309

þ 3OH ! AlðOHÞ3

Al ðAlkaline pHÞ ð1Þ wastewater using an air cathode electrocoagulation (ACEC pro-
cess). Air cathodes developed for MFC applications do not need
to use precious metal catalysts. Instead, inexpensive activated car-
þ 3H2 O ! AlðOHÞ3 þ 3Hþ

Al ðAcidic pHÞ ð2Þ
bon can be used, with the cathode made using various press or roll-
where applied voltages are typically <0.81 V, and the temperatures ing methods [33,34]. The impact of the reactor configuration, such
are usually in the range of 25–50 °C reported. The flocs that form as electrode spacing, operational conditions, and treatment time,
have a large surface area that can adsorb soluble organic com- were examined using two solutions: domestic wastewater, which
pounds and trap colloidal particles in the wastewater [10]. Various contains high concentrations of residual organic matter; and a sim-
metals have been examined to improve process performance [13], ulated treated wastewater, prepared by adding ammonia and
but commonly aluminum or iron is used [8,14–18] due to the good phosphorus to deionized water, to examine the impact on nutrient
performance of these metals for domestic and textile wastewaters, removal in the absence of organic matter. Aluminum mesh anodes
as well as for pesticides and arsenic [18–20]. were used to produce a higher active surface than flat plate elec-
While EC processes are effective for treatment of many types of trodes. Power requirements were examined for different opera-
wastewaters, applications have been limited due to high energy tional conditions to achieve high nutrient removals while
demands and high current densities. Examples include: oil in minimizing power consumption.
wastewater at 25 mA cm2 [21] and 4–30 mA cm2 [22], berberine
hydrochloride removal from a pharmaceutical factory wastewater
2. Materials and methods
at 19 mA cm2 [23], food wastes from restaurants at 30–80 A m2
[24], 50–200 A m2 for hexavalent chromium treatment in an
2.1. Reactor construction
industrial wastewater [25], heavy metal ions removal from a metal
plating wastewater at 4 mA cm2 with 6.3 kWh m3 energy con-
Cube-shaped ACEC reactors were constructed based on a previ-
sumption [26]. EC has also been used for drinking water treatment
ous design [35] and contained a 3 cm diameter electrolyte chamber
to remove hardness and fluoride, but at very high applied voltages
and an air cathode. Reactor lengths of 0.5, 1, 1.5, and 2 cm were
of 24 V, with 22 A m2 and a treatment time of 1 h [27,28]. The
used to examine the impact of electrode spacing on performance,
advantage of the EC process is that treatment can be accomplished
with the electrodes placed on opposite ends of the chamber
without the need for additional chemicals or pre-treatment, but
(Fig. 1). The reactive surface area of each electrode was 7 cm2.
energy costs need to be reduced for EC processes to become more
The anode was a single piece of aluminum mesh (mesh size 200
applicable.
per 2.54 cm, wire diameter 0.05334 mm, opening 0.07366 mm;
The cathodic reaction in an EC process is usually hydrogen evo-
TWP Corporation). Cathodes contained an activated carbon cata-
lution, or oxygen reduction supported by wastewater aeration.
lyst, and were made by a continuous rolling and press process,
Both of these approaches require energy that is not intrinsically
using polytetrafluoroethylene (PTFE) as the binder, and a PTFE/Car-
part of the treatment process. Hydrogen evolution is thermody-
bon black diffusion layer to avoid water leakage [36].
namically unfavorable, and requires a cathode potential of
0.414 V under standard conditions [29]. While oxygen reduction
is thermodynamically favorable, the production of dissolved oxy- 2.2. Solutions
gen requires aeration, which is an energy consuming process. For
example, wastewater aeration in an activated sludge process con- Wastewater was collected from the primary clarifier of the Penn
sumes about 0.6 kWh m3 [30]. Air cathodes are commonly used in State Wastewater Treatment Plant and stored at 4 °C. The waste–
many types of electrochemical systems such as hydrogen fuel cells water had a pH of 7–7.2, and contained 490 ± 10 mg L1 COD,
and microbial fuel cells (MFCs) [31,32], to provide oxygen to the 200 ± 6 mg L1 TSS, an ammonia concentration of 52 ± 4 mg-
cathode. The use of an air cathode avoids energy losses due to aer- N L1, and a total phosphorus concentration of 3 ± 0.1 mg-P L1.
ation, while providing a favorable reaction at the cathode. How- The ratio of N:P in this wastewater was 17:1, and many wastewa-
ever, air cathodes have not been previously examined for ters often have a total nitrogen concentration about ten times that
nutrient removal from wastewater using EC systems. of phosphorus. The solution used to simulate treated wastewater
Air cathodes were examined here as a method to reduce elec- was prepared by adding NH4CI and NaH2PO4H2O (Sigma Aldrich)
trochemical energy requirements for nutrient removal from to deionized water at an initial N:P ratio of 10:1, at four different

A Air-breathing cathode B

Alumunium mesh anode


Fig. 1. (A) Schematic diagram and (B) photo of the electrocoagulation reactor with an air cathode.
310 Y. Tian et al. / Chemical Engineering Journal 292 (2016) 308–314

initial concentrations of 50, 125, 250, 500 mg-N L1 (5, 12.5, 25, 1.5 cm was used in all subsequent tests to minimize variations in
50 mg-P L1). anode performance. Salt precipitates were observed on the cathode
following these tests. These salts were removed by intermittent
2.3. Reactor operating conditions soaking of the cathode in an acid solution.

To select an appropriate operation time based on stable current, 3.2. Wastewater treatment at a fixed applied voltage
the reactor was operated in continuous flow at a hydraulic reten-
tion time (HRT) of 1 h using a peristaltic pump (Cole Parmer, The effectiveness of the ACEC for nutrient, COD, and TSS
USA), at a voltage of 0.5 V set using a potentiostat (VMP3; BioLogic, removal was examined using domestic wastewater at electrolysis
Claix, France), at an electrode spacing of 1.5 cm. In all other tests, times ranging from 0.5 to 6 h (fixed applied voltage of 0.5 V). There
the reactor was operated in fed-batch mode. To evaluate the was a nearly linear decrease in ammonia, COD, and TSS with elec-
impact of electrode spacing distance on performance, the electrode trolysis time, while phosphate removal increased more rapidly,
spacing was varied from 0.5 to 2 cm (based on electrode distances with smaller changes in concentrations at the longer treatment
used in previous studies) [37–39]. times (Fig. 3). Overall changes in concentrations varied from:
Treatment of domestic wastewater was examined at electroly- 15–88% for NH+4–N, 50–99% for PO3 4 –P, 51–71% for COD, and
sis times ranging from 0.5 to 6 h (0.5 V applied voltage, 1.5 cm 22–77% for TSS. The current densities varied over a relatively small
electrode spacing). Treatment efficiency was further examined at range of 6–6.7 A m2 in these fixed-voltage tests. These results
various current densities at a fixed electrolysis time under constant show that there was an increase in the total nitrogen and phospho-
current density operation mode. Synthetic wastewater without the rus removal over time, with nearly complete phosphorus removals
presence of other ions and suspended solids was examined for the at the longer treatment times. Thus, after only 2 h there was nearly
removal of NH+4 and P–PO3 4 at the set conditions of 0.5 V applied 93% removal of phosphorus to a concentration of only 0.2 mg L1,
voltage, 1.5 cm electrode spacing and 4 h electrolysis time. Voltage compared to 40% of nitrogen removal to 31 mg L1. After 6 h, there
and the counter electrode potentials were recorded at 10 s inter- was 88% removal of nitrogen.
vals, and analyzed using EC-Lab V10.02 software. The cathode
was cleaned every ten tests by soaking the cathode in a diluted 3.3. Wastewater treatment at constant current
(10%) hydrochloric acid solution (BDH ARISTAR PLUS, VWR) for
2 min to remove salt deposits. All tests were conducted using Treatment was further examined under conditions of a fixed
duplicate reactors at 30 °C. current densities over the cycle of 6 A m2 (similar to that obtained
at a fixed voltage) to 12 A m2 (Fig. 4). Higher current densities
2.4. Solution measurements and calculations

Total suspended solids (TSS) were measured using standard


methods [40]. Total COD was measured using method 5220 (HACH
Company, Loveland, CO). For nutrient measurements, all samples
were filtered through 0.45 lm pore diameter syringe filters
(polyvinylidenedifluoride, PVDF, 25 mm diameter; Restek Corpora-
tion) and analyzed using Method 10031 (HACH Company, Love-
land, CO) for NH+4–N, and Method 10127 (HACH Company,
Loveland, CO) for P–PO3 4 [40]. Removals were calculated based
on initial and final concentrations. A probe (SevenMulti, Mettler-
Toledo International Inc.) and meter (SevenMulti, Mettler Toledo,
OH) were used to measure solution pH and conductivities.
Energy consumption W (kWh m3) for EC treatment of wastew-
ater was calculated as W = UIt/v, where U is the voltage (V), I the
current (A), t the electrolysis time (h), and v the volume (m3).

3. Results and discussion

3.1. Current generation as a function of time and electrode spacing

Current production examined over time in continuous flow


mode (1.5 cm electrode spacing, 1 h HRT) showed that there was
an initial rapid decrease in current from 7.5 to 5.8 mA over the first
0.6 h, and that current was relatively constant at 6.0 ± 0.5 mA for
the next 6.4 h (Fig. 2A). The subsequent decline in current at longer
treatment times was likely due to losses of aluminum from the
small mesh anode used in these tests (Fig. 2A). Therefore, a work-
ing time of 4 h was chosen for subsequent fed-batch tests to ensure
uniform operational conditions.
Changing the electrode spacing from 0.5 to 1 cm improved the
current density, but larger electrode distances (1.5 and 2 cm)
reduced current (applied voltage of 0.5 V) (Fig. 2B). The stability Fig. 2. (A) Example of change in current over time using a single aluminum mesh
cathode with domestic wastewater, under continuous flow conditions (1.5 cm
of the current generated was also affected by the electrode spacing, electrode spacing, 0.5 V applied voltage, and 1 h HRT). (B) Current densities
with the smallest variation in current (±0.5 mA) obtained with a produced using different electrode distances under fed batch conditions (0.5 V, 4 h
1.5 cm electrode spacing. As a result, an electrode spacing of electrolysis time).
Y. Tian et al. / Chemical Engineering Journal 292 (2016) 308–314 311

improved removal of all wastewater constituents, with phosphate The use of current densities in the range of 8–12 A m2 did not
removal increased from 95% to 99% when the current density was substantially improve removals. Therefore, these results showed
increased from 6 to 8 A m2, and NH+4–N removal increased from that a current density of 8 A m2 was sufficient for achieving good
79% to 96%. Lower removals were achieved for organic matter nutrient removals from domestic wastewater at a treatment time
and solids, with 81% removal of COD, and 89% removal of TSS. of 4 h.

Fig. 3. Removals as a function of electrolysis time using domestic wastewater at a set voltage of 0.5 V, for: (A) NH+4–N, (B) PO3
4 –P, (C) COD, and (D) TSS (1.5 cm electrode
spacing).

Fig. 4. Performance of the ACEC at different fixed current densities using domestic wastewater for: (A) NH+4–N, (B) PO3
4 –P, (C) COD, and (D) TSS (1.5 cm electrode spacing, 4 h
electrolysis time).
312 Y. Tian et al. / Chemical Engineering Journal 292 (2016) 308–314

3.4. Nutrient removal using synthetic wastewater of the domestic wastewater examined here (52 mg-N L1, 3 mg-
P L1). Ammonia removal (93%) at the lowest NH+4–N concentration
In order to examine possible impacts of COD and TSS on perfor- was significantly higher than that achieved using the actual
mance, nutrient removal was examined using nutrients added at wastewater (75%), showing that the organic matter and TSS in
different concentrations to deionized water, at a fixed N:P ratio the wastewater negatively affected nitrogen removal (Fig. 5). In
of 10:1 (50–500 mg-N L1, 5–50 mg-P L1). All other experiment addition to the removal of ammonium ions by the Al(OH)3, the
conditions were similar to the experiments with the wastewater fluid near the cathode can reach a high pH, which results in the
treatment (0.5 V voltage, 1.5 cm electrode spacing and 4 h electrol- conversion of NH+4 to NH3 [41]. This formation of ammonia can
ysis time). The lowest nutrient concentrations were similar to that therefore result in volatilization and loss of ammonia from the
solution, which may have resulted in improved nitrogen removal
here. This possible loss of ammonia by this mechanism will require
further study.
Phosphorus removal (76%) at the lowest nutrient loading was
much lower than that achieved with the wastewater (99%), indi-
cating the presence of COD and TSS improved phosphorus removal.
The greater removal of phosphorus in the wastewater samples sug-
gests that the presence of suspended solids in the flocs was impor-
tant for increasing removal of phosphorus. The higher removal of
phosphate in wastewater compared to synthetic water indicates
phosphate was present largely in insoluble form and the soluble
phosphate was mainly removed by precipitation followed by inclu-
sion into the flocs containing TSS.
Higher initial nutrient concentrations resulted in lower removal
(Fig. 5), with ammonia removals decreased from 93% to 75% and
phosphorus removal decreased from 76% to 45%. Due to higher
conductivity at higher nutrient concentration, flocs were more
readily formed and accumulated at the bottom of the reactor, cre-
ating a larger local current between anode and cathode. As a result,
more anode mass was consumed to generate precipitates deposit-
ing on air cathode, hindering oxygen transfer. In addition, future
improvement on reactor configuration can be made to increase
the removal efficiency for high nutrient loading wastewater.

3.5. Energy consumption

Nutrient removal increased with applied current, although this


increased the energy consumed. The energy used for treating
domestic wastewater in the set current tests ranged from
0.4 kWh m3 (6 A m2) for 79% N removal and 95% P removal, to
Fig. 5. Removals of (A) NH4+–N and (B) PO43–P in a synthetic treated wastewater
9.9 kWh m3 (12 A m2) for 99% removal of both N and P (Fig. 6).
solution (0.5 V applied voltage, 1.5 cm electrode spacing, 4 h electrolysis time).
Considering the balance of energy consumption and nutrient

Fig. 6. Removals of nutrients, in the domestic wastewater, COD and TSS in domestic wastewater compared to energy consumption at a fixed current density (1.5 cm electrode
spacing, 4 h electrolysis time).
Y. Tian et al. / Chemical Engineering Journal 292 (2016) 308–314 313

Fig. 7. Nutrients removals and the energy consumption using a synthetic treated wastewater solution (0.5 V voltage, 1.5 cm electrode spacing, 4 h electrolysis time).

Table 1
Energy consumption of electrocoagulation and removals of phosphorus, nitrogen, COD and TSS reported in different studies using Fe or Al electrodes.

Electrode type Wastewater type Energy (kWh m3) Current density (A m2) Removals (%) References
Al and Fe Landscape water 3 10 90 (total phosphorus) [47]
Al and Al Domestic wastewater 4.5 10 99 (PO3
4 –P); 10 (nitrate); 40 (COD) [43]
Al and Al Synthetic solution 0.4–15 10 52–90 (PO34 –P) [42]
Al and Fe Synthetic solution 22 10 97 (PO3
4 –P) [9]
Al and air-cathode Domestic wastewater 0.4–9.9 6–12 97–99 (PO3 +
4 –P); 79–99 (NH4–N); This study
68–82 (COD); 65–90 (TSS)
Synthetic solution 0.4–2.3 4–23 44–76 (PO3 +
4 –P); 74–95 (NH4–N) This study

removal, a current density of 8 A m2 provided a good balance in to phosphorus removal. In order to take into account all the rele-
nutrient removal (96% ammonium ion removal, and 98% phos- vant variables that impact power production and nutrient removal,
phate removal), and energy demand (1.8 kWh m3). it will be necessary in future studies to examine a wider range of
For tests without high concentrations of organic matter, at variables, using a multivariate analysis, as done by others for eval-
nutrient concentrations (52 mg-N L1 and 3 mg-P L1) similar to uating other technologies [44–46].
wastewater, the energy demand was 0.4 kWh m3 (fixed applied
voltage of 0.5 V, average current density of 6.2 A m2). Nutrient
4. Conclusions
removals (93% N and 76% P removal) in this test were similar to
that obtained in the fixed current tests at 6 A m2. Energy demands
The ACEC process based on using an air-breathing cathode
increased with higher initial nutrient concentrations, with
achieved a nearly linear removal of nitrogen over time (up to
0.5 kWh m3 for 125:12.5 mg L1 tests (N:P), up to 2.33 kWh m3
6 h), with a final removal of 88% of nitrogen, when operated at a
for the 500:50 mg L1 nutrient concentrations (Fig. 7). The higher
fixed applied voltage of 0.5 V. Phosphorus was removed to a
energy demands were likely due to higher electrode overpotentials
greater extent, with 93% of P removed within 2 h. When the system
with the increased concentrations of precipitates formed in the
was operated at a set current density of 8 A m2, rather than a fixed
tests.
voltage, there was up to 99% PO3 +
4 –P and NH4–N removal, and 73%
These energy requirements of the ACEC using air cathodes at
COD and 72% TSS removal, at a fixed operation time of 4 h. The
the lower current densities were generally less than those reported
energy requirement of 1.8 kWh m3 with a set current 5.6 mA
in other studies using Al and Fe or Al and Al electrodes (Table 1).
was lower than that reported in most previous studies, as the ACEC
When using a synthetic wastewater, which contained only phos-
process did not require wastewater aeration or mechanical mixing.
phate, the percentages of nutrients removed here were similar to
These results demonstrate that the ACEC system is a promising
those obtained in these previous studies at similar initial nutrient
technology to remove nutrients from treated wastewater, as the
concentrations. However, the ACEC system required less energy
process has both a high efficiency of nutrient removal, and low
than these other studies with synthetic solutions. When the exper-
energy requirements.
iments were conducted using an actual wastewater the AECE sys-
tem removed more phosphorus, and at the same time removed
ammonia, than that reported by others [42]. While phosphorus Acknowledgment
removals were high here and in previous studies (99%), the ACEC
system consumed much less energy and had lower current densi- This research was supported by the grant from the Strategic
ties than previous studies [9,43]. Moreover, the ACEC system Environmental Research and Development Program (SERDP) and
showed excellent removal of ammonia, TSS, and COD in addition a scholarship from the China Scholarship Council (CSC).
314 Y. Tian et al. / Chemical Engineering Journal 292 (2016) 308–314

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