Enhanced photocatalytic degradation of methylene blue using a novel counter-rotating disc reactor

Introduction: This research introduces an innovative photocatalytic reactor designed to address challenges in wastewater treatment, with a focus on enhancing dye degradation and reducing Chemical Oxygen Demand (COD). Methods: The reactor is designed with counter-rotational movements of discs to enhance hydrodynamics and mass transfer, along with a 3D-printed, interchangeable component system to boost efficacy. TiO₂ nanoparticles, composed of 80% anatase and 20% rutile, are thermally immobilized on glass discs. The effectiveness of various treatment variables was assessed through a Central Composite Design (CCD), guided by a Response Surface Methodology (RSM) model. Results: The RSM analysis reveals that the linear, quadratic, and interactive effects of the counter-rotational movements significantly influence the efficiency of dye and COD removal. The RSM model yields coefficients of determination (R²) values of 0.9758 and 0.9765 for the predictive models of dye and COD removal, respectively. Optimized parameters for dye removal include a pH of 6.05, disc rotation speed of 22.35 rpm, initial dye concentration of 3.15 × 10^-5 M, residence time of 7.98 h, and the number of nanoparticle layers set at 3.99, resulting in 96.63% dye removal and 65.81% COD removal under optimal conditions. Discussion: Notably, the reactor demonstrates potential for efficient treatment within a near-neutral pH range, which could reduce costs and resource use by eliminating the need for pH adjustments. The implementation of discs rotating in opposite directions marks a significant advancement in the process of dye removal.