Optimization of calcined eggshell as an effective coagulant for treating colloidal particles in complex effluents in the CPCP industry: mechanistic insights, scale-up design, and comparative analysis with alum

Highly turbid industrial effluent poses significant challenges to environmental sustainability. In this study, we investigated the optimal aggregation kinetics for the removal of colloidal and turbid particles in Cosmetics and Personal Care Products (CPCP) industrial effluent using calcined eggshell (CES) and industrial-grade aluminum sulfate as flocculants. The effluent characteristics were determined following ASTM specifications, and process optimization was carried out using a response surface design approach. The optimal operating conditions at a settling time of 3 min were found to be pH 8, 0.2 g/L dosage of CES, pH 10, and 0.3 g/L of alum dosage. The flocculation efficiencies of CES and alum were found to be 80% and 78%, respectively, demonstrating the effectiveness of both flocculants in removing colloidal particles and reducing turbidity in CPCP effluent. Mechanistic studies revealed that CES achieved particle removal through enmeshment and inter-particle bridging with a significant aggregation rate (1.3 × 10−7) and a lower floc breakup tendency (2.8 × 10−14) compared to alum-sweep flocculation. The hydrodynamics at a velocity gradient of 269s−1 ≤ G ≤ 29s−1 indicated spontaneous agglomeration within a flocculation period of ≤10 min, indicating rapid and efficient particle removal. The findings of this study justify the use of CES as a sustainable and effective option for the removal of colloid/turbid particles from CPCP effluent. The optimized operating conditions and mechanistic insights into the flocculation process contribute to establishing an optimized sedimentation geometry, with specified aspect ratio, detention time, hypothetical settling, and sludge depth for CES, ensuring the favorable stability of the finished CPCP effluent before discharge.