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Abstract The development of effective and workable wastewater treatments is becoming more and more important. Electrocoagulation is one of the more hopeful methods as it is simple and efficient and compared with traditional processes, has the benefits of short treatment times and low sludge production. In the attempt to reduce the capital and operating costs of electroplating plant effluent treatment, simultaneous oil and copper ion removal by electrocoagulation from copper plating plant effluents was studied in a new cell design, the cell anode was (Al or Fe) helical tube placed between two vertical cylindrical (from the same material) screen cathode Several operating conditions, such as the current density, temperature, initial pH, NaCl supporting electrolyte concentration and effect of gas sparging were varied and the corresponding effects were investigated. Under optimum conditions For Al electrodes, 85% of oil was removed in one hour while the % Cu++ removal was 98% in only 15 minutes. Electrical energy consumption for oil removal ranged from 0.0043 to 5.2 (kW.h/kg) while for copper removal ranged from 0.0054 to 7.5 (kW.h/kg) depending on the operating conditions. On the other hand, for Fe electrodes, 88.3% of oil was removed in one hour while the % Cu++ removals reach to 100% in less than 30 minutes. Electrical energy consumption for oil removal ranged from 1 to 10.9 (kW.h/kg) while for copper removal ranged from 1.1 to 8.0 (kW.h/kg) depending on the operating conditions. Merits of the suggested cell such as compactness and the use of internal surface of helical coil anode as a built in cooler to prevent the increase in solution temperature which adversely affect the efficiency of large scale electrocoagulation processes was highlighted.Wastewater treatment with electrocoagulation can produce high quality water, which could be reused as potable water or fresh water for industrial applications. The technique seems to be able to be used as pre-treatment prior to treatment at a biological wastewater treatment plant. However, a thorough economic and ecological comparison of chemical coagulation and electrocoagulation is recommended, because these methods seem to be similar in pollutant destabilization mechanisms, metal consumption and removal efficiency in most applications |