In this study, electrochemical removal of methylene blue
(MB) from
water using commercially available and low-cost flexible graphite
was investigated. The operating conditions such as initial dye concentration,
initial solution pH, electrolyte dose, electrical potential, and operating
time were investigated. The Box-Behnken experimental design (BBD)
was used to optimize the system’s performance with the minimum
number of tests possible, as well as to examine the independent variables’
impact on the removal efficiency, energy consumption, operating cost,
and effluent MB concentration. The electrical potential and electrolyte
dosage both improved the MB removal efficiency, since increased electrical
potential facilitated production of oxidizing agents and increase
in electrolyte dosage translated into an increase in electrical current
transfer. As expected, MB removal efficiency increased with longer
operational periods. The combined effects of operating time–electrical
potential and electrical potential–electrolyte concentration
improved the MB removal efficiency. The maximum removal efficiency
(99.9%) and lowest operating cost (0.012 $/m
3
) were obtained
for initial pH 4, initial MB concentration 26.5 mg/L, electrolyte
concentration 0.6 g/L, electrical potential 3 V, and operating time
30 min. The reaction kinetics was maximum for pH 5, and as the pH
increased the reaction rates decreased. Consequent techno-economic
assessment showed that electrochemical removal of MB using low-cost
and versatile flexible graphite had a competitive advantage.