Global NEST Journal, Vol 13, No 4, pp 412-418, 2011

Copyright© 2011 Global NEST

Printed in Greece. All rights reserved

REMOVAL OF HEXAVALENT CHROMIUM FROM ELECTROPLATING

WASTEWATER BY ELECTROCOAGULATION WITH IRON ELECTRODES
1
K. DERMENTZIS1, * Department of Science
A. CHRISTOFORIDIS2 Laboratory of Chemical Technology and Electrochemistry
E. VALSAMIDOU2 Technological Education Institute (TEI) of Kavala
A. LAZARIDOU2 65404 Agios Loucas, Kavala, Greece
2
N. KOKKINOS2 Department of Petroleum & Natural Gas Technology
Laboratory of Environment Protection
Technological Education Institute (TEI) of Kavala
65404 Agios Loucas, Kavala, Greece

Received: 15/11/10 *to whom all correspondence should be addressed:

Accepted: 02/12/11 e-mail: [email protected]

ABSTRACT
The performance of electrocoagulation using iron electrodes for the removal of hexavalent chromium
from synthetic aqueous solutions and actual industrial electroplating wastewater was studied.
Parameters affecting the electrocoagulation process, such as initial pH, applied current density,
initial metal ion concentration, COD and time of electroprocessing were investigated. The optimum
pH was found to be in the range 4-8. Initial chromium concentrations of 200 – 800 mg L-1 did not
influence its removal rate. Higher concentrations were reduced significantly in relatively less time
than lower concentrations. Increased current density accelerated the electrocoagulation process,
however, on cost of higher energy consumption. Results revealed that best removal was achieved at
a current density 40 mA cm-2. The electrocoagulation process was successfully applied to the
treatment of an electroplating wastewater sample. Its Cr (VI) ion concentration and COD were
effectively reduced under the admissible limits in 50 minutes of electroprocessing.
KEYWORDS: electrochemical coagulation, electroplating effluent, hexavalent chromium, iron
electrode.

1. INTRODUCTION
Heavy metals, such as mercury, lead, chromium, nickel, copper, cadmium and zinc, are of
considerable concern because they are non-biodegradable, highly toxic and probably carcinogen.
Several treatment processes have been suggested for the removal of heavy metals from aqueous
waste streams: adsorption (Lazaridis et al., 2005), biosorption (Senthikumar et al., 2010), ion
exchange (Inglezakis et al., 2003), chemical precipitation (Kurniawan et al., 2006) and
electrochemical methods: electrowinning (Bolger and Szlag, 2004), electrodialysis (Marder et al.,
2004), electrodeionization (Yeon et al., 2003; Lu et al., 2010), membrane-less electrostatic shielding
electrodialysis/electrodeionization Dermentzis et al., 2010) and electrocoagulation.
Chromium is released into the environment from electroplating, anodizing, chromating, metal
finishing, tannery, dying and fertilizer industries (Liu et al., 2011; Vasudevan et al., 2010). Waste
streams from electroplating units may contain up to 2500 mg L-1 Cr (VI), which according to
environmental regulations worldwide must be controlled to an acceptable level before being
discharged to the environment. The permissible limits for Cr (VI) is 0.5 mg L-1 in effluent discharge to
sewage systems and 0.1 mg L-1 in drinking water.
The most common and economical method for hexavalent chromium removal involves reduction to
its trivalent state and subsequent precipitation with alkali. As reducing agents are used ferrous ions,
sulfur dioxide, sodium bisulfite or hydrazinium salts. The reduced trivalent chromium is then
precipitated by addition of an alkali e.g. lime or caustic soda according to reactions (1), (2) and (3):
REMOVAL OF HEXAVALENT CHROMIUM FROM ELECTROPLATING WASTEWATER 413

Cr2O72- + 6Fe2+ + 14H+ → 2Cr3+ + 6Fe3+ + 7H2O (1)

Cr3+ + 3OH- → Cr(OH)3 (2)
Fe3+ + 3OH- → Fe(OH)3 (3)

The produced sludge amount in the above process is very large, since for 1 kg of chromium
removed 32 kg of sludge is generated, which is difficult to handle (Reddithota et al., 2007).
Chemical coagulation is a quite effective method for treating heavy metal bearing wastewaters but
may induce secondary pollution by adding coagulants, such as aluminum or iron salts or organic
polyelectrolytes to remove colloidal matter as gelatinous hydroxides. Also this wastewater treatment
process produces a large amount of sludge.
Electrochemical coagulation or otherwise called electrocoagulation uses no chemicals as
coagulating agents. These are generated during the electrolysis process by electrodissolution of a
sacrificial anode made of aluminum or iron. Electrocoagulation has been successfully performed for
treatment and remediation of textile wastewaters (Dermentzis et al., 2011; Kobya et al., 2003; Raju
et al., 2008), oil wastes (Abdelwahab et al., 2009; Un et al., 2009), diary effluents (Tchamango et al.,
2010), diesel and bio-diesel wastewaters (Chavalparit & Ongwandee, 2009; El-Naas et al., 2009),
laundry wastewaters (Wang et al., 2009), slaughter house effluents (Asselin et al., 2008), arsenic or
fluoride containing waters (Hansen et al., 2007; Hu et al., 2008) and heavy metal bearing effluents
(Adhoum et al., 2004; Heidmann & Calmano 2008; Kongsricharoern & Polprasert, 1996; Nouri et al.,
2010).
The objective of this paper was to investigate the efficiency of electrocoagulation in removing
hexavalent chromium from synthetic aqueous solutions and actual industrial wastewater. In addition,
the effect of pH, current density, initial metal concentration, time of electroprocessing and COD was
investigated.

2. METHODS
2.1 Chemicals
KCl, K2Cr2O7 and NaOH were of analytical grade (Merck). pH was adjusted by 0.1 M solutions of HCl
and NaOH as required. The actual wastewater was obtained from an electroplating unit located near
Thessaloniki, northern Greece.

2.2 Apparatus
A laboratory model DC power supply apparatus (PHYWE Systeme GmbH & Co.) was used to
maintain constant DC current. Voltage and current were measured by a multimeter (PHYWE).
Conductivity was measured by means of a conductometer (WTW). pH and temperature were
measured using a Hanna pH-meter connected to a combined electrode comprising a temperature
sensor.
The chemical oxygen demand (COD) was analyzed using a COD reactor (Thermoreaktor TR 420,
MERCK) and a direct reading spectrophotometer (Spectroquant Pharo100, MERCK).
Electrochemical experiments were conducted at room temperature in a cylindrical glass cell of 400
ml in which aliquot solutions of 200 mL were placed and slowly stirred with a magnetic bar at 500
rpm. Two commercially obtained iron plates were used as electrodes with size 10cm x 5cm x 0.2cm
immersed to a 6 cm depth with an effective area of 30 cm2 each. The interelectrode distance was
1.5 cm. To remove the oxide and passivation layer from iron surface the electrodes were grinded
with sandpaper and energized by dipping them in HCl 5N for 1 minute. 0.5 g KCl was added to every
treated solution. The added KCl served for prevention of passivation on the iron electrode surface
and decrease of the excessive ohmic drop in the solution. The polarity of the cell was reversed every
30 minutes to limit the formation of the passivation layers on the electrodes.
Samples were extracted every 10 minutes, filtered using Whatman filter paper (Grade 40). The
residual chromium concentrations were determined by Atomic Absorption Spectroscopy AAS (Perkin
Elmer 5100). At the end of each experiment the produced sludge was measured.
414 DERMENTZIS et al.

2.3 Brief description of electrocoagulation

Electrocoagulation is a process consisting of creating metallic hydroxid flocs inside the wastewater
by electrodissolution of soluble anodes made of aluminum or iron. The electrochemical oxidation of
iron anodes produces ferrous, Fe2+ and ferric, Fe3+ ions. The Fe2+ ions can reduce Cr (VI) to Cr (III)
in alkaline to neutral medium, while they are oxidized to Fe3+ ions according to reaction (4):

CrO42- + 3Fe2+ + 4H2O + 4OH- → 3Fe(OH)3 + Cr(OH)3 (4)

Both, Fe3+ and Cr3+ ions combine with the generated OH- ions and precipitate as insoluble
hydroxides. The Fe2+ ions can also reduce Cr2O72- ions in acidic medium according to reaction (1),
as already stated. The generated H2 gas produced at the cathode can remove dissolved organics or
any suspended material by flotation. Furthermore, Fe3+ ions undergo hydration and give, depending
on pH, cationic species such as Fe(OH)2+, Fe(OH)22+ in acidic conditions, Fe(OH)3 in neutral
conditions and anionic species such as Fe(OH)4-, Fe(OH)63- in alkaline conditions which finally result
in situ formation of gelatinous Fe(OH)3 effecting the coagulation and co-precipitation from the
solution by adsorption. The iron hydroxide flocs act as adsorbents for heavy metal ions.
Furthermore, heavy metal ions combine with the electro-generated OH- ions at the cathode and
precipitate in form of their insoluble hydroxides. Both phenomena act synergistically leading to a
rapid removal of heavy metal pollutants from water. Fe3+ as a flocculation agent is advantageous,
due to its innocuity compared to Al3+, which shows some toxic effects.

3. RESULTS AND DISCUSSION

3.1 Effects of operating parameters
The electrocoagulation process is affected by several operating parameters, such as initial pH,
pollutants concentration, applied current density, COD and contact time. In the present study all
these have been explored in order to evaluate a treatment technology for chromium removal from
synthetic solutions and actual electroplating wastewaters.

3.1.1 Initial pH
pH has a considerable effect on the efficiency of the electrocoagulation process. In addition, pH
changes during the process dependent on the anode material and the initial pH value of the treated
solution. The increase of pH at initial pH lower than 7 is ascribed to the hydrogen evolution and the
generation of OH- ions at the cathodes (Vik et al., 1984). In alkaline medium (pH>8) the final pH
does not change markedly because the generated OH- ions at the cathodes are consumed by the
generated Fe3+ ions at the anode forming the needed Fe(OH)3 flocs. Furthermore, OH- ions can also
partially combine with Cr3+ ions to form the insoluble hydroxide precipitate Cr (OH)3.
Experiments conducted at different initial pH values in the range 1-10 showed that the removal
percent of chromium is low at pH<2. It increases considerably at pH 4, remains high and almost
constant in the pH range 4-8 and substantially decreases at pH>8. The decrease in removal
efficiency at strong acidic and strong alkaline pH was described by other researchers (Adhoum et
al., 2004; Vasudevan et al. 2009). It was ascribed to an amphoteric behavior of Fe(OH)3 which leads
to soluble cations Fe3+ , Fe(OH)2+, Fe(OH)2+ (at acidic pH) and to monomeric anions Fe(OH)4- ,
Fe(OH)63- (at alkaline pH). It is well known that these species are not usefull for water treatment. For
these reasons the electrocoagulation process was conducted in the pH range 4-8.

3.1.2 Current density

Khosla et al. (1991) reported that the applied current density determines the coagulant dosage rate,
the bubble production rate and size and the flocs growth resulting in a faster removal of pollutants.
Measurements were carried out at different current densities 10-40 mA cm-2, at a constant heavy
metal concentration of 800 mg L-1 and initial pH 7.5. According to Fig. 1 the removal rate of
chromium increased, as expected, with increasing current density. After 40 minutes of electrolysis
time at the current density 40 mA cm-2, Cr (VI) ions have been almost quantitatively removed (>99%)
and their concentration decreased under the admissible limits for effluents discharge to sewage
systems (0.5 mg L-1).
REMOVAL OF HEXAVALENT CHROMIUM FROM ELECTROPLATING WASTEWATER 415

Figure 1. Chromium concentration versus time at different current densities

Cr (VI) ions must first be reduced to Cr (III) ions at the cathode, according to reaction (5), which then
combine with the generated OH- ions and precipitate as insoluble Cr (OH)3 or are adsorbed to the
Fe(OH)3 flocs.
Cr2O72- + 6e- + 7H2O → 3Cr3++ 14OH- (5)
Furthermore, Cr (VI) ions can also be reduced to Cr (III) ions by Fe (II) ions which in turn are
oxidized to Fe (III) ions according the reaction (1) in acidic pH or according to reaction (4) in alkaline
to neutral pH, as already stated in the introductory section 1 and 2.3 respectively. The presence of
ferrous ions enhances the reduction and removal of chromium. Consequently, the removal rate of
chromium by electrocoagulation with iron electrodes is faster compared to that with aluminium
electrodes.

3.1.3 Initial metal ion concentration

To demonstrate the effect of initial metallic pollutant concentration and the time required for its
quantitative removal, a set of experiments was conducted with different initial concentrations 200,
400 and 800 mg L-1 of chromium ions. Each solution was treated at a constant current density of 40
mA cm-2 and different times of electrolysis.

Figure 2. Effect of initial concentration of chromium on its removal efficiency versus time

Fig. 2 shows the variations of the different initial concentrations of chromium and its removal
efficiency with time. The three chromium ion concentrations were reduced to admissible levels in 20,
25 and 40 minutes respectively. According to Fig. 2, no direct correlation exists between metal ion
concentration and removal efficiency. Certainly, for higher concentrations longer time for removal is
416 DERMENTZIS et al.

needed, but higher initial concentrations were reduced significantly in relatively less time than lower
concentrations. The electrocoagulation process is more effective at the beginning when the
concentration is higher than at the end of the operation when the concentration is low.

3.2 Treatment of actual wastewaters

The applicability of the electrocoagulation process for actual wastewater was validated by treating an
industrial effluent sample, collected from an electroplating unit. As known, chromium electrodeposits
are mainly obtained from acidic hexavalent chromium electrolytic baths. During the plating process
Cr (VI) ions contaminate the rinse waters when the plated objects are rinsed upon removal from the
plating bath.
At a constant current density of 40 mA cm-2 and an electrolysis time of 50 minutes the concentration
of chromium decreased under the admissible limits (Fig. 3). The removal efficiency re is very high
(99.9 %). It is calculated from the formula of equation 1:
Co − C
re = × 100 (1)
Co
where Co and C are the initial and final concentrations of chromium ions in the treated wastewater.

Figure 3. Concentration variation and removal efficiency of chromium versus time during the
electrocoagulation treatment of the electroplating wastewater

Compared to the removal from synthetic solutions (Figs 1, 2) the removal rate of chromium from
actual wastewater seems to be slower. This should be attributed to the presence of the organic
compounds, which also compete for adsorption on the Fe (OH)3 flocs resulting in a substantial
reduction of the metal ions removal. The initial COD content of 530 mg L-1 decreased to 183 mg L-1
after 50 minutes of electroprocessing showing a removal efficiency of about 65.5 %. During the
electrocoagulation treatment of the wastewater its initial pH value of 3.5 rose to a final value of 8.4.

3.3 Electrode mass loss and energy consumption

The costs in wastewater treatment with electrocoagulation are the expenditure on mass loss of
electrodes and the electrical energy consumption. The mass loss of the iron anode mFe can be
calculated from equation (2) using the Faraday’s law:
I ⋅t ⋅ M
mFe = (2)
z ⋅ F ⋅V
where
I = current intensity (A)
t = time (s)
M = Molecular weight of iron (g mol-1)
REMOVAL OF HEXAVALENT CHROMIUM FROM ELECTROPLATING WASTEWATER 417

z = number of electrons transferred in the reaction Fe → Fe2+ + 2e-

F = Faraday’s constant (96500 Cb mol-1)
V = wastewater solution volume.
Under the given operating conditions the mass loss of the sacrificial iron anode per liter of the
treated wastewater is 4.34 g Fe L-1.
Similarly, the electrical energy consumption E is calculated from equation (3):
U ⋅ I ⋅t
E= (3)
V
Where: U = voltage (Volts).
The energy consumption amounts to 0.046 kWh L-1 of treated wastewater.

3.4 Sludge characteristics

The precipitated sludge was collected, dried at 103 oC for 24 h, cooled in a desiccator and weighed.
Its amount was determined by the Faraday’s law. Compared to the conventional chemical
precipitation - coagulation process, electrocoagulation produces apparently lower amount of sludge.

4. CONCLUSIONS
Electrocoagulation with iron electrodes is a safe, reliable, convenient and efficient route for removal
of heavy metals, such as chromium and COD from water and industrial wastewater. Best removal
efficiency was achieved in the pH range 4-8. Removal rate increased with increasing current density.
Initial chromium concentration of 200, 400, 800 mg L-1 in synthetic solutions and 517 mg L-1 in
industrial wastewater at a current density of 40 mA cm-2 reduced under the admissible limits in a
short period of time. Furthermore, the COD in electroplating wastewater was also removed. In
comparison to chemical coagulation, where an increased coagulant dosage and several hours are
needed, electrocoagulation is a faster and more economical method for wastewater treatment.

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