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Reactive dyes are essential materials for the modern lifestyle due to rapid industrialization and urbanization, but they cause adverse effects on the environment. This research work aimed to decolourize the synthetic aqueous solution containing Reactive Black B (RBB) dye using electrocoagulation (EC) process with iron electrodes in batch reactor. The effect of operational parameters such as initial pH (3–9), the distance between electrodes (0.5–2 cm), current density (1.1–8.4 mA/cm2) and initial dye concentration (100–400 mg/L), was investigated in the presence of sodium chloride to maintain the conductivity of electrolytes. Under optimal value of process parameters, high decolourization (99.6%) was obtained at 25 min. The experimental data showed that pseudo-second order kinetics with a correlation coefficient (R2 = 0.97) and Sips isotherm with a correlation coefficient (R2 = 0.98) were found to be well fitted for kinetic and adsorption equilibrium models, respectively. The economic efficiency was also calculated on the basis of electrical energy consumption (EEC), specific electrical energy consumption (SEEC), and current efficiency, respectively. Moreover, characterization of EC generated sludge was also carried out by proximate analysis, IR spectra and XRD analysis. The results revealed that EC process using Fe electrode is quite efficient and clean process for decolourization of reactive dye from aqueous solution.

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The present study is aimed to model and optimize the electrocoagulation (EC) process with five important parameters for the decolorization of Reactive Black B (RBB) from simulated wastewater. A multivariate approach, response surface methodology (RSM) together with central composite design (CCD) is used to optimize process parameters such as pH (5–9), electrode gap (0.5–2.5 cm), current density (2.08–10.41 mA/cm2), process time (10–30 min), and initial dye concentration (100–500 mg/l). The predicted percentage decolorization of dye is obtained as 97.21% at optimized conditions: pH (6.8), gapping (1.3 cm), current density (8.32 mA/cm2), time (23 min), and initial dye concentration (200 mg/L), which is very close to experimental percent decolorization (98.41%). The statistical analysis of variance (ANOVA) is performed to evaluate the quadratic model (RSM), and shows good fit of experimental data with coefficient of determination R2 >0.93. An Artificial Neural Network (ANN) is also used to predict the percentage decolorization and gives overall 94.96% which shows performance accuracy between the predicted and actual value of decolorization. The additional considerations of operating cost and current efficiency are also taken care to show the efficacy of EC process with mathematical tool. The sludge characteristics are determined by FE-SEM/EDX.