In this study bio-flocculant extracted from the de-oiled cake, a common waste generated while producing oil was used to treat an electroplating industrial effluent. A comprehensive analysis of flocculation efficiency in a simulated reactor using ANSYS Workbench - Fluent, with a focus on optimizing impeller position was carried out. The findings reveal that the optimal impeller position is 2 cm from the tank base, where maximum turbulent kinetic energy (0.02577 m2/s2) and dissipation rate (22.19 m2/s3) were achieved at 200 RPM, enhancing flocculation efficacy. Furthermore, the study identifies 0.5 g L−1 as the optimal flocculant dosage, resulting in 72.70 % and 89.38 % removal of Ni(II) and Cr(VI), respectively. The flocculation process was determined to follow second-order kinetics, with significant improvements in collision efficiency and particle aggregation at the optimized dosage. Fourier Transform Infrared spectroscopy analysis confirmed chemical interactions leading to flocculation, while zeta potential and particle size distribution studies corroborated the stability and effectiveness of the process. A techno-economic analysis was conducted, estimating the total capital investment required for pilot and industrial-scale implementations, highlighting the feasibility and scalability of the proposed treatment method. A holistic framework for enhancing industrial effluent treatment processes by integrated computational fluid dynamics, kinetic studies, and economic evaluation, is the novelty of this research.
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