Application of Response Surface Methodology for the Optimization of Basic Red 46 Dye Degradation in an Electrocoagulation-Ozonation Hybrid System

The release of synthetic dyes like Basic Red 46 (BR46) from industrial wastewater has raised growing concerns due to their toxicity, long-term persistence, and resistance to standard biological treatment methods. In this work, we developed and tested a pilot-scale electrocoagulation-ozonation (EC-O) hybrid system aimed at removing BR46 from aqueous solutions. The system integrates electrocoagulation, using iron electrodes, with ozone-based advanced oxidation processes, facilitating a combination of coagulation, adsorption, and oxidative breakdown of dye molecules. The response surface methodology (RSM) with a central composite design (CCD) was applied to optimize the treatment process, focusing on five variables: current density, flow rate, ozone dosage, ozonation time, and initial dye concentration. The quadratic model exhibited strong predictive power, with an adjusted R² of 0.9897 and a predicted R² of 0.9812. The optimal conditions identified included a current density of 70 A/m², flow rate of 1.6 L/min, ozone dose of 2.0 g/h, and an ozonation time of 20 min, achieving a predicted removal efficiency of 91.67% for a solution with BR46 at an initial concentration of 300 mg/L. Experiments conducted under these conditions confirmed the model's reliability, with observed removal rates exceeding 90% and deviations under 2%. The EC-O system had a treatment capability of 26.19 L/h and an energy consumption of 3.04 kWh/m³. These findings suggest that the EC-O system is an effective and scalable option for treating dye-contaminated wastewater, offering faster and more efficient results than conventional techniques.