Treatment of petroleum refinery wastewater by electrofenton process using a low cost porous graphite air-diffusion cathode with a novel design

A low-cost micro porous graphite air diffusion cathode (MPGADC) has been utilized successfully for the in-situ hydrogen peroxide generation via O2 reduction in 0.05 M Na2SO4. Using a tubular electrochemical reactor with a novel design composed of MPGADC as a cathode and a hollow cylinder porous graphite as an anode, a maximum of 68 mg/ L of H2O2 was produced at a current density of 25 mA/cm2, an air flow rate of 3 L/min, and a pH value of 3. Electro-Fenton (EF) process was adopted to remove the chemical oxygen demand (COD) from the wastewater of Al-Dora petroleum refinery in Iraq using this new style of tubular electrochemical reactor. Based on the response surface methodology (RSM) with Box-Behnken design (BBD), the effect of EF operating parameters on the COD removal was investigated.The optimal conditions for maximizing COD removal efficiency (RE%) with lowering specific energy consumption (SEC) using EF process were determined to be a current density of 6.66 mA/cm2, Fe2+ concentration of 0.80 mM, and an electrolysis duration of 60 min, in which RE% of 94% with SEC of 3.75 kWh/kg COD were achieved. In addition, the results demonstrated that the current density has the greatest influence on the COD removal, followed by electrolysis duration and then Fe2+ concentration. Furthermore, current density has the greatest impact on the specific energy consumption, followed by time, while Fe2+ concentration has a negligible effect. The high R2 value (98.33%) confirmed the goodness of fitting the model equation. These results established the viability of employing the new cathode design for the EF process in treatment of petroleum refinery wastewaters.(c) 2023 Institution of Chemical Engineers. Published by Elsevier Ltd. All rights reserved.