Treatment of real industrial-grade dye solutions and printing ink wastewater using a novel pilot-scale hydrodynamic cavitation reactor

A novel pilot-scale hydrodynamic cavitation (HC) reactor was used to decolorize industrial-grade dye solutions and printing ink wastewater (PIW). The effect of the orifice plate geometry (1 hole plate of 1 mm and 2 mm in diameter, 31 holes of 1 mm and 2 mm in diameter, 62 holes of 1 mm and 2 mm in diameter), inlet pressure (4, 5 bar), initial dye concentration (0.3 and 0.6 OD), and the synergistic effect of HC and hydrogen peroxide concentration (0.0, 0.5, 1.0, 2.0 g/L) were investigated. The results showed that the highest color removal was obtained using 31 holes orifice plate of 2 mm holes’ diameter, at 4 bar inlet pressure. Furthermore, although HC could not degrade completely all the industrial-grade dyes, efficiency was enhanced in the presence of H₂O₂. The optimum concentration of hydrogen peroxide was 1.0 g/L regardless of the initial concentration of the dyes studied. Under optimum operating conditions, color removal reached up to 68% for black, 39% for red, 43% for yellow, 55% for green, and 51% for cyan dye, while color removal in the PIW reached only 15%. The black dye solution presented almost 100% COD removal, while 38%, 25%, 67%, and 78% COD removal values were obtained for the red, yellow, cyan and green dyes, respectively. 55% COD removal was recorded from the PIW. Concerning cavitation yields, black, red, yellow, green, cyan dye yields reached 2.5E(-7), 1.1E(-7), 1.5E(-7), 2.0E(-7), 1.7E(-7) OD⋅L/J, respectively, while PIW yield was 6.3E(-8) OD⋅L/J. The present study demonstrates that HC combined with green oxidants such as hydrogen peroxide could be an alternative treatment approach for real industrial wastewater streams. However, a combination with a post-treatment method should be applied to maximize both color and COD removal.