Physicochemical Treatment of Electroplating Wastewater: Efficiency Evaluation and Process Optimization

Electroplating wastewater poses a serious environmental threat due to its high concentrations of heavy metals and persistent organic pollutants. This study evaluated the efficiency of a combined coagulation and activated carbon filtration process for the treatment of real electroplating wastewater containing Ni2+, Zn2+, Cu2+, and Cr6+ ions. The research was conducted in two stages. In the first stage, laboratory-scale experiments were performed to determine the optimal coagulant type (Fe- and Al-based), dosage, and pH (5.0–10.0) for contaminant removal. In the second stage, the selected operating conditions were applied and validated under real industrial plant conditions at a pilot scale. The laboratory studies demonstrated that the highest Cr removal efficiency was achieved using an iron-based coagulant (PIX), while polyaluminum chloride (PAX) proved most effective for the removal of Ni and Zn. Subsequent filtration through activated carbon further enhanced heavy metal removal, increasing overall efficiencies to above 90%. The reported removal efficiencies represent the overall performance of the integrated treatment process. The results confirm that the integration of chemical coagulation and activated carbon filtration is an effective, environmentally friendly, and economically viable approach for treating real electroplating wastewater, enabling compliance with current environmental standards.