Efficient removal of COD, BOD, oil & grease, and turbidity from oil-field produced water via electrocoagulation treatment.

The simple design, compactness, simultaneous treatment of multiple contaminants, absence of chemical usage, minimal sludge formation (reducing secondary pollution), low maintenance cost, and versatility to operate in both batch and continuous modes make electrocoagulation (EC) a promising choice for treating various types of industrial wastewater. In this study, EC was employed in batch mode to treat produced water obtained from an oil drilling site, to reuse it for injection purposes in the reservoir. Produced water typically contains high levels of total dissolved solids (TDS), turbidity, chemical oxygen demand (COD), biological oxygen demand (BOD), and oil & grease (O&G) contaminants. High-performing aluminum (Al) electrodes were chosen due to their stability, conductivity, and, most significantly, their high capacity for generating aluminum hydroxide ([Al(OH)₃]ₙ) flocs, which serve as carriers for contaminant capture. This compound has demonstrated remarkable effectiveness in trapping the aforementioned contaminants from produced water under various operating conditions, including the number of electrodes, supplied current, and electrode configuration (bipolar and monopolar). The impact of several factors, including the number of electrodes (varying from 4 to 8), current density (varying as 16, 79, 158 A/m), and electrode configuration (bipolar and monopolar), was studied at room temperature and 250 rpm agitation speed. Initial turbidity, COD, BOD, and O&G concentrations were measured at 38 NTU, 700.7 ppm, 120 ppm, and 32.8 ppm, respectively. The EC treatment exhibited removal efficiencies of 51% for TDS, 85% for turbidity, 78% for COD, 80% for BOD, and 85% for O&G using a monopolar configuration with 8 electrodes, and 59% for TDS, 90% for turbidity, 85% for COD, 84% for BOD, and 86% for O&G using a bipolar configuration with eight electrodes. Additionally, cost estimation, considering electrode dissolution rate and power requirements, was conducted for the operation of both configurations.