Separation of nanoscale oil droplets in the cutting-oil emulsion by electrocoagulation-flotation (ECF) was carried out in a bubble column reactor (BCR) and an external-loop airlift reactor (ALR). Under the batch operation, aluminium electrode provided the highest efficiency of 99% and required the shortest separating time compared to iron and graphite electrodes. The separation performance was also affected by the electrode gap and current density due to the amount of produced aluminium ions and turbulence by bubble motions. Additionally, the ECF efficiency obtained from the ALR was similar to that of the BCR. However, the ALR was preferable owing to its lower energy consumption, less electrode sacrifice, and less sludge production. Similar results were acquired under the continuous mode; nevertheless, the highest efficiency of only 85% was achieved from both reactors. It was found that the efficiency declined with increasing flow rates. According to the results suggested by the residence time distribution (RTD), the ALR was more effective at higher flow rates since the plug flow condition can be retained. On the other hand, an increase in flow rate also provoked the bypass flow to the down-comer of the ALR, resulting in the presence of a dead zone and reduction in the treatment efficiency.
Keywords: Cutting-oil emulsion; airlift reactor; bubble column reactor; electrocoagulation–flotation; residence time distribution.