Modeling and optimization of acid dye manufacturing wastewater treatment with Fenton's reagent: Comparison with electrocoagulation treatment results and effects on activated sludge inhibition

In the present study, Fenton's oxidation of a chromium complex disazo dye (Acid Blue 193) synthesis wastewater was evaluated, modeled and optimized by employing Central Composite Design. Within this context, the individual and interactive effects of critical process parameters such as Fe²⁺, H₂O₂ concentrations, initial chemical oxygen demand (COD) and reaction time was assessed. The process response (output) variables were chosen as percent color, COD and total organic carbon (TOC) removal efficiencies. Optimum working conditions in terms of color and organic carbon removals were established to be Fe²⁺ = 3 mM; H₂O ₂ = 25 mM; reaction time = 10 min at pH 3 and an initial COD content of 245 mg/L. Under these conditions, 96% color, 82% COD and 51% TOC removals were obtained. The established polynomial regression models describing color, COD and TOC removals satisfactorily fitted the experimental data and could be used to predict Fenton's treatment results at statistically significant rates. Optimized treatment results were compared with those obtained via electrocoagulation treatment under optimized conditions (applied current = 50 A/m²; reaction time = 15 min; initial pH = 7 for an initial COD content of 245 mg/L). The relative inhibition of heterotrophic oxygen uptake rate was measured to examine the inhibitory effect of azo dye synthesis effluent before and after Fenton's oxidation and electrocoagulation with respect to synthetic domestic wastewater. Untreated azo dye production wastewater exhibited a slightly inhibitory effect that was appreciably reduced but not entirely removed after Fenton's oxidation, whereas no inhibition of mixed bioculture was observed for azo dye synthesis effluent subjected to electrocoagulation treatment.