Electrocoagulation (EC) of Orange II dye in a flow through cell with aluminum as sacrificial electrodes was carried out under varying conditions of dye concentration, current density, flow rate, conductivity, and the initial pH of the solution in order to optimize the operating parameters for maximum benefits. Maximum removal efficiency of 94.5% was obtained at the following conditions: dye concentration=10 ppm, current density=160 A/m(2), initial pH 6.5, conductance=7.1 mS/cm, flow rate=350 mL/min, and concentration of added NaCl=4.0 g/L of dye solution. The EC-floc was characterized using Fourier transform infrared spectroscopy, scanning electron microscopy/energy dispersive X-ray spectroscopy, and powder X-ray diffraction techniques. The removal mechanism has been proposed that is in compliance with the Pourbaix diagram, solubility curve of aluminum oxides/hydroxides, and physico-chemical properties of the EC-floc.
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