Textile dye effluent treatment using advanced sono-electrocoagulation techniques: A Taguchi and particle swarm optimization modeling approach

Abstract

ABSTRACT The removal of reactive black-WNN dye from aqueous solutions was optimized using Taguchi optimization (TA) and particle swarm optimization (PSO) modeling in a batch mode potentiometric sono-electro-coagulation (SOEC) process with the aid of aluminum plates. The optimization process was based on four influencing factors: pH, current density (CD), electrolysis time (ET), and ultrasonic power (UP). A Taguchi orthogonal array L25 design matrix was used to optimize these factors to maximize the dye removal efficiency. The analysis of variance showed that the percentage of contribution of ET, pH, CD, and UP was 67.64%, 12.83%, 5.03%, and 6.80%, respectively. PSO modeling was found to be a better tool for predicting dye removal efficiency than TA optimization, with a prediction error of 1.17% compared to -4.63%. Under the optimized conditions of pH-6.6, CD-66.66 mA/cm2, ET-25 minutes, and UP-100 W, the dye removal efficiency was found to be 98.30%, with a total energy consumption of 0.1188 kW h/L. The kinetic degradation study between ET and CD was found to follow a second-order kinetic model. Additionally, the synergistic effect was evaluated by combining ultrasonication and electrocoagulation. The results showed that the combined process (sono-electrocoagulation) was more effective than either ultrasonication or electrocoagulation alone, with a synergistic effect of 15%. Overall, the results suggest that TA optimization and PSO modeling can be effective tools for optimizing process parameters in the removal of Reactive black-WNN dye from aqueous solutions. The optimized conditions identified in this study, as well as the demonstration of the synergistic effect, can be used to design more efficient treatment systems for the removal of dyes from wastewater.