General Potential-Current Model and Validation for Electrocoagulation

A model relating potential and current in continuous parallel plate iron electrocoagulation (EC) was developed for application in drinking water treatment. The general model can be applied to any EC parallel plate system relying only on geometric and tabulated input variables without the need of system-specific experimentally derived constants. For the theoretical model, the anode and cathode were vertically divided into n equipotential segments in a single pass, upflow, and adiabatic EC reactor. Potential and energy balances were simultaneously solved at each vertical segment, which included the contribution of ionic concentrations, solution temperature and conductivity, cathodic hydrogen flux, and gas/liquid ratio. We experimentally validated the numerical model with a vertical upflow EC reactor using a 24 cm height 99.99% pure iron anode divided into twelve 2 cm segments. Individual experimental currents from each segment were summed to determine total current, and compared with the theoretically derived value. Several key variables were studied to determine their impact on model accuracy: solute type, solute concentration, current density, flow rate, inter-electrode gap, and electrode surface condition. Model results were in good agreement with experimental values at cell potentials of 2-20 V (corresponding to a current density range of approximately 50-800 A/m2), with mean relative deviation of 9% for low flow rate, narrow electrode gap, polished electrodes, and 150 mg/L NaCl. Highest deviation occurred with a large electrode gap, unpolished electrodes, and Na2SO4 electrolyte, due to parasitic H2O oxidation and less than unity current efficiency. This is the first general model which can be applied to any parallel plate EC system for accurate electrochemical voltage or current prediction.