Optimising zero-valent iron from industrial waste using a modified air-Fenton system to treat cutting oil wastewater using response surface methodology

Abstract

This study investigates the treatment of cutting oil wastewater from the automotive parts manufacturing industry to promote sustainability via the use of ‘used shot blasts’, which are the by-products of auto parts production. Used shot blasts are rich iron sources of Fe 0 , which becomes an effective catalyst in the Fenton reaction. A modified air-Fenton (MAF) system was proposed to generate hydroxyl radicals that eliminated recalcitrant organics in cutting oil wastewater. First, the Taguchi method, comprising the L18 orthogonal array design, was used to identify significant operation factors, including the size and amount of used shot blasts, initial pH, reaction time, mixing speed, initial cutting oil concentration, and air flow rate. Then, a central composite rotatable design coupled with response surface methodology (RSM) was used to determine the optimal conditions and model the influencing variables. The results provided three crucial variables for the cutting oil wastewater treatment through use of the MAF system: initial pH, the amount of used shot blasts, and initial cutting oil concentration. RSM was applied to reveal the optimum operating conditions, achieving a maximum removal efficiency of 92.82% for chemical oxygen demand (COD), 80.18% for total organic carbon (TOC), and 99.55% for turbidity within 45 min of operating the MAF system. The model agreed well with the experimental data, with coefficient of determination values of 0.9819, 0.9654, and 0.9715 for COD, TOC, and turbidity removal efficiency, respectively. Pseudo-second-order reaction kinetics fitted well for COD removal, with a rate constant of 0.0218 min −1 and hydrogen peroxide generation of 0.0169 M. Overall, the proposed MAF system was efficient and had a low operating cost (0.67 USD/m 3 ).