Design and Techno-economics of an Electrocoagulation-Based Combined System for Fluoride Removal from Groundwater

High fluoride concentrations in subterranean water pose health risks, especially in the Global South. This study aims to develop and assess the effectiveness of an integrated water treatment unit that has been designed to remediate fluoride pollution via electrocoagulation at Changsari, Assam, India. The unit incorporates aeration, electrocoagulation (EC), flocculation, sedimentation, and dual media filtration for treating 20 m3 day–1 groundwater. Iron and fluoride removal efficacies were 94 and 89%, respectively, lowering contaminants below IS 10500 standards. The operational cost was US$0.25 per cubic meter, making it economically feasible compared to previously conducted research. Innovative aspects of this study include a 12 week operational performance and stability assessment, a precise estimation of capital costs for large-scale electrocoagulation-based systems, a novel electrode life calculation method using a safety factor, and a comprehensive techno-economic analysis of operating costs including water quality testing. The results emphasize the need for an electrocoagulation-based integrated treatment process and consistent monitoring to guarantee the availability of safe drinking water. These contributions bridge the gap between laboratory studies and large-scale implementations, providing a cost-effective, scalable solution for mitigating fluoride contamination in groundwater resources and making the study industry relevant.