Optimized electrocoagulation with stacked aluminum disc electrodes for ammonia removal from wastewater

• A novel stacked-disc aluminum anode was designed for ammonia removal by EC. • Optimal ammonia removal achieved at pH 2.85, 0.9 mA/cm 2 , and 1.3 g/L NaCl. • Reactor design enhanced surface area, mixing, and coagulant generation. • Findings support energy-efficient ammonia removal for industrial wastewater. This study investigates an optimized electrocoagulation (EC) system for ammonia removal from wastewater using a novel stacked aluminum disc electrode design. Response surface methodology (RSM) was employed to optimize key parameters, including pH, current density, NaCl dosage, and initial ammonia concentration. The optimum conditions were identified as pH 2.85, current density 0.9 mA cm -2 , NaCl concentration 1.3 g L -1 , and ammonia concentration 43 ppm, achieving high removal efficiency with reduced energy consumption. The stacked-disc electrode configuration enhanced surface area and hydrodynamics, improving both treatment performance and energy efficiency. These findings demonstrate the potential of the system as a cost-effective and scalable solution for decentralized wastewater treatment.