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Abstract
In this study, the decolorization of strong colored solutions containing the reactive textile dyes by electrocoagulation was inves-
tigated. The experiments were statistically designed and carried out according to a 24 full factorial design with two replicate and
four center points. This design was extended with eight additional axial points. Then, the non-linear regression was applied on the
data by using MINITAB software. The variables chosen for this work are mixing rate, cell voltage, electrolysis time and current
density. Results showed that the effective variables on decolorization process are cell voltage, electrolysis time and current density.
In addition, to determine the effect of dye and electrode type on decolorization, the additional experiments were carried out. It was
determined the dye and electrode type are important on the decolorization process. # 2002 Elsevier Science Ltd. All rights reserved.
Decolorization%
The variables chosen for this work are cell voltage,
I Rep. II Rep. Run x1 x2 x3 x4
current density, electrolysis time and mixing rate. From
experimental observations, it was assumed that the 20.16 15.36 1 1 1 1 1
higher order interactions were small relative to the low 34.56 29.76 2 1 1 1 1
24.96 20.16 3 1 1 1 1
order interactions, because a system with several process
46.52 46.52 4 1 1 1 1
variables is conducted primarily by some of the main 32.16 32.16 5 1 1 1 1
effects and low order interactions. Therefore, the pre- 100.00 100.00 6 1 1 1 1
sent work considers only two-way interactions. The 29.76 24.96 7 1 1 1 1
other higher order interactions have been added in the 100.00 100.00 8 1 1 1 1
22.56 22.56 9 1 1 1 1
error. The center points could be used to check the cur-
34.56 34.56 10 1 1 1 1
vature in the model to be fitted (Bennett and Franklin, 29.76 22.56 11 1 1 1 1
1967; Hines and Montgomery, 1990; Strange, 1990). 34.56 39.32 12 1 1 1 1
Before statistical analysis, the main variables were mod- 24.96 24.96 13 1 1 1 1
ified to their variables coded in the following manner: 100.00 100.00 14 1 1 1 1
36.92 24.96 15 1 1 1 1
X1, X2, X3 and X4 are original variables, where X1, X2,
100.00 100.00 16 1 1 1 1
X3 and X4 represent electrolysis time (min), cell voltage 29.76 17 0 0 0 0
(V), current density (mA cm2) and mixing rate (rpm), 36.96 18 0 0 0 0
respectively. Accordingly, x1, x2, x3 and x4 are the coded 34.56 19 0 0 0 0
variables, where 27.36 20 0 0 0 0
x1 ¼ ðX1 10Þ=5
shows that the exception for x4,as the factor levels are
x2 ¼ ðX2 110Þ=2:5 increased, decolorization percentage increases. Fig. 3
shows the plots of interactions for four main variables.
x3 ¼ ðX3 3Þ=1 The significant interactions are indicated by non-paral-
lel lines on the plots. As can be seen from this figure,
x4 ¼ ðX4 600Þ=200 there are two important interactions: the first one is
between electrolysis time (x1) and current density (x3)
The levels for the four main variables were chosen and the second one is between cell voltage (x2) and cur-
from our previous experiences. The original and coded rent density (x3). Since the existence of curvature masks
levels are given in Table 1. The full factorial design is the importance of the main effects, a reduced model in
given in Table 2. In order to determine the influence of which center points are eliminated was used. The var-
the main variables on the decolorization, the data was iance analysis table of reduced model is given in Table 4.
statistically analysed by using MINITAB software and From Table 4, it can be seen that the main effects and
the results are given in Table 3. As can be seen from two-way interactions which are significant at 0.05 level
Table 3, the P value (0.000 for curvature) clearly shows are x1, x2, x3, x1*x3 and x2*x3, respectively. As can be
existence of curvature. The P values for main effect seen from Table 3, a curvature exists. Therefore, a
(0.000) and two-way interaction (0.000) are very small. quadratic or higher order model will be convenient to fit
This indicates that at least one of both the main effects to the obtained data. However, since the data was not
and the interactions is important. The main effect plots enough for the higher order model, eight axial points
of the four variables are given in Fig. 2. This figure were added to experimental design. The results obtained
494 A. Gürses et al. / Waste Management 22 (2002) 491–499
Table 3
Analysis of variance for decolorization percentage
from additional experiments are given in Table 5. The In addition, to order to determine the influence of
final model obtained for Remazol Red RB dye and Fe electrode type and dye types on decolorization, the
electrode is as follows: additional experiments with two replicates were carried
out under the conditions for run 6 given in Table 2. The
Decolorization % ¼ 29:9 þ 22:1x1 þ 2:52x2 þ 17:8x3 obtained data have been statistically analysed. Results
of two-way variance analysis (ANOVA) of these
þ 14:0x1 x3 1:49x2 x3 þ 4:47ðx1 Þ2 experiments have been given in Table 6. From this table,
it can be seen that at least one of dyes and electrodes
þ 7:61ðx3 Þ2 þ 5:15ðx1 Þ2 ðx3 Þ2 chosen are important (P=0.000) and also there is
strong interaction between them (P=0.000). this inter-
For this equation, s (root MSE) and R2 values (the action are graphically shown in Fig. 4. Because of the
multiply coefficient of determination) are 4.592 and interaction between the variables, the dyes and electro-
98.2%, respectively. des can be compared with each other by performing
A. Gürses et al. / Waste Management 22 (2002) 491–499 495
Table 4
Full factorial fit for the reduced model (without center points)Estimated effects and coefficients for decolorization percentage
Table 5 Table 6
Additional runs for decolorization process Two way variance analysis for influence of electrode and dye types
Table 7
One way variance analysis for influence of electrode and dye types and individual 95% confine intervals for mean based on pooled standard deviation
Source DF SS MS F P
E, electrode; Fe, iron; Al, aluminium; Gr, graphite; D, dye; R, red RB; O, orange 3R; Y, yellow GL; B, blue 3R new.
variation of zeta potentials and conductivities with electrolysis time. Figs. 5a and b show that at the begin-
electrolysis time could give the more information for the ning of electrolysis, monomeric hydrolysis products
interaction. The results related to variation of the values with low concentration is main products in the relative
of both the zeta potentials and the conductivities with acidic medium. Thus, the colloidal particles having zero
electrolysis time for Fe, Al and Graphite electrode are and negative zeta potential value are produced by
given in Figs. 5–7, respectively. adsorption of the negatively charged dye molecules on
Ferric ions electrogenerated may form monomeric the monomeric hydrolysis products (Gregory, 1993;
ions, ferric hydroxo complexes with hydroxide ions and Rebhun and Lurie, 1993; Oxspring et al., 1995). This
polymeric species, namely, Fe(H2O)+3 6 , Fe(H2O)5 causes somewhat to increase in the decolorization per-
OH+2, Fe(H2O)4(OH)+1 2 , Fe2(H2O)8(OH)2
+4
and Fe2 centage. However, after the electrolysis of 7.5 min, the
+2
(H2O)6(OH)4 , depending on pH range (Johnson and zeta potential values of the colloidal particles increase
Amirtharajah, 1983). The complexes (i.e. hydrolysis negatively with the increasing medium pH up to 7. As
products) have a pronounced tendency to polymerize at can be seen from Fig. 5a and b, after this time (7.5 min),
pH 3.5–7.0 (Pykhteer et al., 1999). When Fe electrode is the decolorization percentage has been reduced. This is
used, the amount and the variety of hydrolysis products may be due to the restabilization. On the other hand,
formed by anodic dissolution depends significantly on the different trends in Fig. 5b can be attributed to
Fig. 5. The plots for the variation of the decolorization percentages, zeta potential values and conductivities with the electrolysis time at the several
d.a.c. in the case of Fe electrode.
A. Gürses et al. / Waste Management 22 (2002) 491–499 497
Fig. 6. The plots for the variation of the decolorization percentages, zeta potential values and conductivities with the electrolysis time at the several
d.a.c. in the case of Al electrode.
Fig. 7. The plots for the variation of conductivities with the electrolysis time at the several d.a.c. in the case of graphite electrode (a) with the dye (b)
without the dye.
change in the formation rate of hydrolysis products, as low pH range is explained as precipitation while the
a result of the increasing current density (i.e. as a result higher pH range ( > 6.5) as adsorption (Rebhun and
of the shortening of the anode–cathode distance). Lurie, 1993).
In the experiments in which Al electrode is used, the
electrogenerated aluminium ions may form monomeric Precipitation : DYE þ Monomeric AI !
and polymeric hydroxo complexes, depending on the ½DYE Monomeric AI
ðsÞ pH ¼ 4:05:0
pH range (Johnson and Amirtharajah, 1983). These ð1Þ
complexes have tendency to polymerize in the pH 4–7
ranges. Oversaturation and formation of amorphous DYE þ Polymeric AI !
hydroxide precipitate AI(OH)3(H2O)3s enmeshes colloi-
dal particles in a ‘‘sweep floc’’. Many monomeric and ½DYE PolymericAI
ðsÞ pH ¼ 5:06:0
polymeric species such as AI(OH)+2, AI(OH)+ 2 , AI2 ð2Þ
(OH)+42 , AI(OH) 4, AI6(OH)+3
15 , AI7(OH)+4 17 , AI8 Adsorption : DYE þ AIðOHÞ3 ðsÞ ! ! ½particle
(OH)+4 +7 +5
20 , AI13O4(OH)24 , AI13(OH)34 have been repor-
ted (Rebhun and Lurie, 1993). Formation rates of the ð3Þ
different species play an important role in decolorization
process. Several interaction mechanisms are possible ½DYE PolymericAI
ðsÞ þ AIðOHÞ3 ðsÞ
simultaneously between dye molecules and hydrolysis
! ! ! ½particle
mainly exist in the medium. Under these conditions, the effect of the dye types on electrocoagulation process
electrostatic charge neutralization between these hydro- can be explained with the pronounced dependence of
lysis products and hydrolyzed negatively charged dye the hydrolysis species to anode-cathode distance and
molecules occurs [Eqs. (1) and (2)]. As a result of this electrolysis time. This can also be attributed to the dif-
process, aggregation tendency of the monomeric hydro- ferent adsorptive properties of dyes. In addition, from
lysis products increases. As can be seen from Fig. 6a, at the regression analysis of all 44 runs, a mathematical
the end of this time (2.5 min), the small amount of the equation showing the relation between decolorization
dye removes by adsorbing on the aggregates. Also, the percentage and the effective variables was obtained. The
results (Table 7) indicate that the formation of coagu- high R2 square value of 98.2% for this mathematical
late depend on the structure of the dyes chosen and so model indicates the presence of a high correlation
on the adsorption ability of dye molecules on hydrolysis between observed and predicted values.
products or flocs. The negative zeta potentials values
also support this mechanism. On the other hand, at
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