Application of Response Surface Methodology for the Optimization of Basic Red 46 Dye Degradation in an Electrocoagulation–Ozonation Hybrid System

The release of synthetic dyes like Basic Red 46 (BR46) from industrial wastewater has raised growing concerns due to their toxicity, long-term persistence, and resistance to standard biological treatment methods. In this work, we developed and tested a pilot-scale electrocoagulation–ozonation (EC–O) hybrid system aimed at removing BR46 from aqueous solutions. The system integrates electrocoagulation, using iron electrodes, with ozone-based advanced oxidation processes, facilitating a combination of coagulation, adsorption, and oxidative breakdown of dye molecules. The response surface methodology (RSM) with a central composite design (CCD) was applied to optimize the treatment process, focusing on five variables: current density, flow rate, ozone dosage, ozonation time, and initial dye concentration. The quadratic model exhibited strong predictive power, with an adjusted R2 of 0.9897 and a predicted R2 of 0.9812. The optimal conditions identified included a current density of 70 A/m2, flow rate of 1.6 L/min, ozone dose of 2.0 g/h, and an ozonation time of 20 min, achieving a predicted removal efficiency of 91.67% for a solution with BR46 at an initial concentration of 300 mg/L. Experiments conducted under these conditions confirmed the model’s reliability, with observed removal rates exceeding 90% and deviations under 2%. The EC–O system had a treatment capability of 26.19 L/h and an energy consumption of 3.04 kWh/m3. These findings suggest that the EC–O system is an effective and scalable option for treating dye-contaminated wastewater, offering faster and more efficient results than conventional techniques.