Scale-up of an electrochemical reactor for treatment of industrial wastewater with an electrochemically generated redox mediator

This paper presents the results of a study on the scale-up, from a batch to a continuous flow unit, of an electrochemical reactor applied for the treatment of textile wastewater. Decolourisation of the wastewater bearing a reactive dye Red Procion H-EXGL proceeded via indirect electro-oxidation, mediated by “active chlorine”. The kinetics of decolourisation in a single-cell reactor under different operating conditions were second order, with the highest apparent rate constant (k = 0.523 l mol⁻¹ s⁻¹) achieved at 40 °C. A low Hatta number (Ha = 0.03) indicated that the reaction occurred totally in the bulk solution, hence homogeneous reaction kinetics were used successively to scale-up a continuous flow electrochemical unit: a once-through filter-press reactor. Its hydrodynamic characteristics were defined by the residence time distribution (E(t)) function using a pulse injection method. The decolourisation efficiency experimentally determined in a continuous flow reactor was further compared with that predicted on the basis of the knowledge of the E(t) of the reactor and the homogeneous phase kinetic expression, obtained from the batch study and corrected for the geometric parameters of the reactors. A complete segregation of the fluid inside the flow reactor was assumed. For different applied flow rates, the experimentally defined conversion of the dye was close to the calculated value.