Study on the removal of hazardous Congo red from aqueous solutions by chelation flocculation and precipitation flotation process.

Dyes are intensively used in textile and dyeing industries, and substantial volumes of organic wastewater with residual dye require treatment before discharges to public waterways. Flotation separation is an efficient and widely used method for the treatment of massive organic dye wastewaters. The key scientific problems for dye flotation separation lie in the mineralization transformation of dissolved dye to tangible flocs. In this work, a high-efficiency removal of hazardous azo dye Congo red (CR) from simulated wastewaters via metal ions chelation flocculation followed by flotation separation was proposed. It's demonstrated that CR can be chelated by the trivalent metal ions, including Al(III), Fe(III), and its mixture to form hydrophobic flocs, and then the flocs were efficiently removed via flotation in a microbubble column. The effects of chelation flocculation and flotation separation conditions on the removal efficiencies of CR, COD, and chromaticity from CR simulated wastewaters were optimized. Chelation effect of CR by trivalent metal ions was in this order: Al(III)+Fe(III)>Fe(III)>Al(III). The chelation mechanism suggested that CR molecules gradually changed from hydrazones to electronegative azo with the increase of pH to 6-7, and electrostatic attraction between the Al(OH) or Fe(OH) with the CR was favorable for the chelation reaction, in which the metal ions chelated with N atoms on naphthalene ring and amino groups of CR. Over 99% CR was removed under the optimal chelation and flotation conditions: chelation by composite Al(III)/Fe(III) with a concentration of 25 mg/L at pH of 7 for 25min; followed by flotation with SDS concentration of 20 mg/L and air flow rate of 50 mL/min for 20min. Under this condition, the COD and chromaticity removal efficiency were over 96% and 98%, respectively, and the turbidity was lower than 0.1 NTU, meeting the water discharge requirement. Eventually, resourceful utilization of flotation sludge via calcination was conducted to prepare Al-Fe spinel refractory material.