Design and testing of a pilot scale magnetic separator for the treatment of textile dyeing wastewater

Iron nanoparticles can be incorporated on the structure of natural clays to obtain magnetic clays, an adsorbent that be easily removed from a wastewater by magnetic means. Magnetic clays have high adsorption capacities of different contaminants such as heavy metals, fungicides, aromatic compounds and colorants and show rapid adsorption kinetics, but crucial data for achieving its full or pilot scale application is still lacking. In this work, magnetic bentonites with different amounts of magnetite (iron fractions on the clay of 0.55, 0.6 and 0.6) were used to remove color from a real textile wastewater. On a first stage the optimal conditions for the adsorption of the dye, including pH, temperature and clay dosage were determined. Also design parameters for the separation process such as residence time, distance from magnet to magnetic clay and magnet strength were obtained. Finally a pilot scale magnetic drum separator was constructed and tested. A removal of 60% of the dye from a wastewater that contained more than 250 ppm of azo dye was achieved with only 10 min of residence time inside the separator.