Use sacrificial metal anodes to generate coagulants in-situ, eliminating external chemical dosing while breaking emulsions and removing dissolved metals.
Electrocoagulation (EC) uses an electrical current to dissolve sacrificial metal anodes (typically iron or aluminium) directly into wastewater. The dissolved metal ions hydrolyse to form polymeric hydroxide species that coagulate and flocculate contaminants. Simultaneously, electrolytic reactions at the cathode produce hydrogen micro-bubbles that assist flotation. EC is particularly effective for emulsified oils, stable colloids, and situations where external chemical dosing is undesirable or supply is unreliable.
Coagulant generated in-situ from anode dissolution – no ferric, alum, or polymer delivery needed.
EC sludge is denser and more dewaterable than chemical coagulation sludge – 40% less volume.
Electrolytic reactions generate oxidative species that reduce bacterial counts by 2-4 log.
Coagulant dose controlled by current density (A/m2) – digital ammeters provide real-time control.
Step-by-step breakdown of the treatment process from influent to effluent.
Flow and pH equalized to provide stable conditions for EC. Optimal pH range 5.0-8.0 for iron anodes, 5.0-7.5 for aluminium.
Rectifier supplies DC current (10-50 A/m2) to parallel plate electrodes. Iron anodes dissolve at 1 g/Ah. Contact time 15-45 minutes.
Gentle mixing for 10-20 minutes allows Fe(OH)3 or Al(OH)3 flocs to grow and enmesh contaminants. Polymer may be added for heavy loads.
Hydrogen micro-bubbles from cathode rise at 0.3 m/h, carrying flocs to surface. Alternatively, lamella clarifier captures settling flocs.
Float skimmed or sludge scraped. Effluent filtered through sand or cartridge to capture carryover. Final pH adjusted if needed.
Explore the equipment components that make this process effective.
Stainless steel tank with parallel plate electrodes, DC rectifier, auto-polarity reversal.
Thyristor-controlled rectifier 0-500A, automatic current density control.
High-rate settling for EC floc capture at 4-6 m/h upflow.
Acid/alkali dosing for optimal EC pH and final discharge pH.
Break petroleum and food oil emulsions without demulsifying chemicals.
Remove humic acids, heavy metals, and ammonia from leachate.
Treat process wastewater containing colloidal silica and organics.
Remove fats and proteins from high-strength food processing waste.
This treatment stage is engineered to achieve specific contaminant removal targets while providing stable, predictable performance across variable inlet conditions. Design parameters are calculated from wastewater characterisation data, regulatory requirements, and site-specific constraints including footprint, energy availability, and operator capability.
Design validated by CFD modelling and pilot testing to confirm performance guarantees.
Equipment selected for 20-year design life with minimal wearing parts and easy access.
Automated dosing and feedback control minimise reagent consumption and sludge production.
Online monitoring and data logging demonstrate continuous consent compliance.
| Design Flow | 10 – 5,000 m³/h (application specific) |
| Inlet Variability | Designed for 1:3 peak-to-average flow ratio |
| Removal Efficiency | 85 – 99% depending on target contaminant |
| Hydraulic Retention | Calculated from kinetic constants and safety factors |
| Power Consumption | 0.5 – 5.0 kWh/100 m³ (process dependent) |
| Chemical Dose | Auto-controlled based on online analysers |
| Sludge Production | 0.2 – 1.5 kg DS/kg contaminant removed |
| Materials | SS304, SS316L, or carbon steel with coating |
No treatment stage operates in isolation. This process is designed to receive conditioned influent from upstream stages and deliver effluent quality suitable for downstream processes. Hydraulic and organic loading rates are balanced across the complete treatment train to prevent bottlenecking and ensure overall plant efficiency. Our engineers model the complete flowsheet to optimise Capital expenditure and Operating expenditure across the plant lifecycle.
Screening, equalisation, and pre-treatment protect this stage from damage and overload.
Effluent quality ensures downstream biology, filtration, or disinfection performs optimally.
Reject streams, filtrate, and centrate are routed back to appropriate upstream points.
Our engineers design and commission complete treatment systems including all equipment, automation, and commissioning support.
Our expertise spans multiple industries with sector-specific water treatment solutions.