Electrochemical Degradation of Methylene Blue by a Flexible Graphite Electrode: Techno-Economic Evaluation

[Image: see text] 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.