TECHNICAL MANUAL

FLAGSHIP
Electro Contaminant Removal (ECR) DHAKA
Science, Systems and Applications
ECR Capabilities ECR Benefits
 Removes heavy metals as oxides  Low capital & operating costs
 Removes suspended and colloidal solids  Low power & maintenance requirements
 Breaks oil emulsions in water & Removes FOG  Handles wide variations in the waste stream
 Destroys & removes bacteria, viruses, and cysts  NO chemical additions = Sludge minimization
 Processes multiple contaminants at various levels  Treats multiple contaminants for Water reuse
Rationale Due to the development of various industry sectors such as textile, oil & gas exploration,
electroplating, tannery, industries in general; a large amount of wastewater is generated during the
production. Wastewaters contain high concentration of pollutants, toxins, COD, BOD, salts, metals,
color, etc. Many treatment processes have been developed for wastewater such as biological,
evaporation, integrated aeration and ozonation, chemical processes, etc. However, all these treatment
schemes, individually, are impractical or unviable. Considering the majority of wastewater
purification operations; the electro-chemical procedure has been proven and found to be a reliable
process because of its low sludge generation, low start-up and operating costs, no chemical additions
into the treated water and high treatment efficiencies. One more process has been developed to the
commercial stage and is being used on several industrial wastewaters in S.E. Asia. The ECR process
is known as Electro Contaminant Removal (ECR) or more commonly known as electrocoagulation,
electro-deposition, electro-flotation, electro-oxidation, etc.

ECR Science is based on valid & proven principles involving responses of water pollutants/
contaminants to electric fields and electrically induced oxidation and reduction reactions.

ELECTRO CONTAMINANT REMOVAL

Solids Spectrum Reduction / Removal Range

ST Microscope Scanning Electron Microscope Optical Microscope Visible to Naked Eye

Micrometer
(Log scale) Ionic Range Molecular Range Macro Molecular Range Micro Particle Range Macro Particle Range

Albumin Protein Yeast Cells

Aqueous salts Paint Pigment
Carbon Black

Endotoxin/ Pyrogen Bacteria

Atomic
Relative Radius
A. C. Fine dust Granule
SIZE of Sugar Virus
Activated
Tobacco Smoke
Common Synthetic dye Milled Flour Carbon
Latex / Emulsion
Pollutants Pesticide Blue Indigo Dye Pollen

Herbicide Colloidal silica Asbestos Coal Dust Human Hair

Metal Ions
Gelatin Crystosporodium Giardia cyst

Process for REVERSE ULTRAFILTRATION PARTICLE FILTRATION

Separation OSMOSIS
NANOFILTRATION
MICROFILTRATION

Contractor – Office of U.S. NAVAL RESEARCH Mickley & Assoc., Boulder Colorado
December 2004
“Pretreatment Capabilities and Benefits of ECR”
“The results do clearly indicate the most beneficial application of ECR in terms of
providing pretreatment is to membrane systems. The use of ECR in front of a
multi-membrane systems of UF/RO or MF/RO has promise to improve
performance of the membrane system and to broaden its application to include
feed water having high suspended solids levels”.
Coagulation and Electro-coagulation Chemical coagulation has been used for decades to
destabilize suspensions and to effect precipitation of soluble metal species, as well as other inorganic
species from aqueous streams, thereby permitting their removal through sedimentation or filtration.
Alum, lime, and/or polymers have been the chemical coagulants used. These additions, however,
tend to generate large volumes of sludge with high bound water content that can be slow to filter and
difficult to dewater. These treatment chemicals also tend to increase the total dissolved solids
content of the effluent, making it unacceptable for reuse within industrial applications.

The Flagship ECR System offers an alternative to the use of metal salts or polymers and poly-
electrolyte addition for breaking stable emulsions and suspensions. The system removes metals,
colloidal solids and particles, and soluble inorganic pollutants from aqueous media by introducing
highly charged polymeric metal hydroxide species. These species neutralize the electrostatic charges
on suspended solids to facilitate agglomeration and resultant separation from the aqueous phase. The
ECR offers an additional step by taking advantage of the technology’s inherent electro-flotation
mechanism; wherein hydrogen gas is released at the cathode surface. Electro-floatation simply
floats pollutants to the surface of the water wherein it is mixed with hydrogen and oxygen generated
from water electrolysis. Each Unit employs diffused air to expedite the floatation process thus
allowing water solids to pass between individual electrodes and remain afloat longer; thus allowing
the bulk/ majority solids to be removed from the surface instead of waiting for the precipitation
process to occur. By removing the bulk surface solids, smaller and less complicated conventional
clarification devises can be employed.

The pH, pollutant type and concentration, the bubble size and position, floc stability and
agglomerate size all influence the operation of the ECR unit. The overall mechanism is a
combination of mechanisms functioning synergistically. The dominant mechanism may vary
throughout the dynamic process as the reaction progresses. The dominant mechanism will almost
certainly shift with changes in operating parameters and pollutant types.

Highly charged cations destabilize any colloidal particles by the formation of polyvalent
polyhydroxide complexes. These complexes have high adsorption properties, forming aggregates
with pollutants. Evolution of hydrogen gas aids in mixing and hence flocculation. Once the floc is
generated, the electrolytic gas creates a flotation effect removing the pollutants to the floc - foam
layer at the liquid surface. There are a variety of ways in which species can interact in solution:

1. Migration to an oppositely charged electrode (electrophoresis) and aggregation due to charge

neutralization.
2. The cation or hydroxyl ion (OH-) forms a precipitate with the pollutant.
3. The metallic cation interacts with OH- to form a hydroxide, which has high adsorption properties
thus bonding to the pollutant (bridge coagulation).
4. The hydroxides form larger lattice-like structures and sweeps through the water (sweep
coagulation).
5. Oxidation of pollutants to less toxic species.
6. Removal by electroflotation and adhesion to bubbles.

Journal of Hazardous Materials Gebze Institute. Turkey March 2003

“Treatment of TEXTILE Wastewaters by ECR using Iron &
Aluminum electrodes” Department of Environmental Engineering.
“The electro generated flocs separate rapidly and remove color and
turb-idity form dyeing waste waters. The process has been found to
be very efficient in COD removal and de-coloration
with low-energy consumption”.
DESCRIPTION of the ECR System In its simplest form, an ECR reactor is made up of
electrolytic cells with one anode and one cathode. When connected to an external power source, the
anode material will electrochemically corrode due to oxidation, while the cathode become passive.
But, this arrangement is not suitable for wastewater treatment, because for a workable rate of metal
dissolution, the use of electrodes with large surface area is required. This has been achieved by using
cells with electrodes either in parallel or in double configurations. ECR cell arrangements are either
parallel or doubled as shown below.

Parallel Cell Double Cell

For Conductive Waste Waters For Non- Conductive Waste Waters

ECR essentially consists of pairs of conductive metal plates placed between two parallel electrodes
and a dc power source. The conductive metal plates are commonly known as "sacrificial electrodes"
or common mild steel. The sacrificial anode lowers the dissolution potential of the anode and
minimizes the passivity of the cathode.

The parallel arrangement of plates is electrically similar to a single cell with many electrodes and
interconnections. In double cell arrangement, a higher potential difference is required for a given
current to flow because the cells connected in series have higher resistance. The same current would,
however, flow through all the electrodes. On the other hand, in Parallel cell arrangement the electric
current is divided between all the electrodes in relation to the resistance of the individual cells.

ECR bipolar electrodes with parallel cells are preferred because less electricity is required. In this
instance the sacrificial electrodes are placed between the two parallel electrodes without a middle
electrical connection.

This cell arrangement provides a simple set-up, which facilitates easy maintenance during use. When
an electric current is passed through the two electrodes, the neutral sides of the conductive plates
will be transformed to charged sides, which have opposite charge compared to the parallel side
beside it.

Thus, during ECR, the positive side undergoes anode reactions, while on the negative side, cathode
reaction is encountered. The released ions neutralize the charges of the particles and thereby initiate
coagulation. In addition, as water containing colloidal particulates, oils, or other contaminants move
through the applied electric field, there may be ionization, electrolysis, hydrolysis, and free-radical
formation which may alter the physical and chemical properties of water and contaminants. As a
result, the reactive and excited state causes contaminants to be released from water and destroyed or
made less soluble.

Colorado Hazardous Waste Management Society MTS Journal. Vol. 27, No. 1 67 1989
“ECR Treatment of Ship Bilgewater for the U.S. Coast Guard
in Alaska”“The results show that electrocoagulation treatment is effective in
destabilizing oil emulsions. Removal efficiencies (extractable oil) exceeded
99% resulting in non-detectable values of less than 0.2mg/L TPH values in
the effluent. The process was also effective in removing heavy metals with
removal efficiencies ranging from 71 to 99%”.
Tech SYSTEM OVERVIEW The common element of ECR passes electricity through water. The
physical chamber to induce the electricity in the water varies greatly. The chambers vary in flow
rate & electrical input configuration, etc. The basic principal is to cause electrons (amps) to flow
through the liquid. The reaction takes place on the surface interface between liquid and blades.
Electro Chemical Reaction Chamber
ECR is the distinct economical and environmental
choice for meeting water treatment standards and

compliance requirements. ECR recovers capital and

operating costs by eliminating the need for chemicals,
discharge fees and fines, harvesting water resources,
and significantly reducing water replacement costs.
Cost of sacrificial metal used within the chamber The conductive material in the ECR unit
will dissolve and provide a coagulation nucleus from the blades like Fe++ and Al ++. Because the
conductive material dissolves and must be replaced periodically, the form of that material has direct
operating cost considerations. The ECR uses common metal bar stock in standard widths available
directly from the steel mill.
Surface area configuration ECR treatment occurs at the surface interface between the liquid
and the conductive material. Flat plates allow distances to be set that are far enough apart to lessen
the clogging caused by large particles in the water, and close enough together to lessen the amount
of voltage required to move the electricity through the liquid. The ECR chamber is designed with
3.5mm cells.

Directional flow ECR in general causes air to be liberated from the water. Air bubbles float to
the top of any liquid. The bubbles can attach to the surface of the conductive material which blocks
the metal liquid interface. The lack of conductivity within the chamber will prevent electrons from
passing through the liquid which stops the treatment process. The ECR chamber directs water flow
in the same direction as air bubbles float. The system eliminates pressure and resistance because the
water flows in the same direction as the air bubbles thus ECR blades do not need to withstand
pressure. The ECR units use standard 3-3.6mm thick sheet stock. Because the ECR blades are not
specialty cut with lasers or precision machined, the cost is only the price of the steel.

Electrical connections Electricity enters the chamber in anode and cathode pairs. The voltage
between the anode and cathode pairs must be set by transforming the grid power to the voltage
desired between the pairs. The cost of transformers and the cost of electrical conductors to handle
the amperage between the anode and cathode pairs greatly limit the flow rate of traditional outdated
chambers. The ECR reaction chamber and its bipolar design allows direct line voltage to be
converted from AC to DC and this saves the weight and space of electrical transformers. This also
allows for the energy efficiency of operating the power at less than 3 volts per gap between blades,
which saves on electrical consumption and it eliminates the need to connect an electrical conductor
to each plate, which saves on the labor and blade construction cost. Electrical cost savings depends
upon the voltage difference applied between the conductive materials. Power is purchased in watts.
A watt is a volt times an amp.

Flow rate within the chamber Units operate at atmospheric pressure. Because the conductive
material has no pressure requirement, the chamber can be built to meet any flow rate. However,
operational constraints such as the weight and size of steel plates play an important role in
determining chamber size. Unit designs are built in 5-15, 10-30, 30-60, 60-120, 120-180M3 per
hour configurations for one man operations. Actual flow rates can increase or decrease based on
specific conductivity factors of a given wastewater stream. Multiples chambers are configured with
high quality electrical requirements for specific waters and power delivery per flow rates.
 Scientific Conclusions The fact that ECR technology is now successfully applied to contaminated
water around the world is testament to its existing application to the RMG Sector in BD. The ECR Water
System has clearly preformed some of the more complex requirements needed to remove a wide range of
wastewater pollutants.: See references found at www.flagshipdhaka.com :

The below results are provided by customers and/or have been reported by an Analytical Laboratory!

INDUSTRIAL INFLUENT into a Water Treatment Works Plant SINGAPORE – DHAKA / 2005 - 2017

JT-ECR
JT- JT-ECR JT-ECR JT-ECR JT-ECR JT-ECR JT-ECR
X= No
RAW A1 A2 A3 B1 B2 B3
Not Tested Amps

.25 A 1.0 A 2.5 A 5.0 A 1.0 A 2.5 A 5.0 A

ECR Settings x x x X x x x
35V 70V 110V 175V 70V 110V 175V

0.036 0.30 1.146 3.646 0.167 0.637 2.025

Power Consumption /
KWH KWH KWH KWH KWH KWH KWH
M3

REGIONAL RESULTS

Parameter RAW ECR ECR ECR ECR ECR ECR ECR Method
Units
Name Results Results Results Results Results Results Results Results Reference
BOD 638 388 359 338 321 389 325 338 mg/L APHA 5210B
COD 1150 875 867 865 844 881 822 812 mg/L USEPA 410.4
Copper 5.38 0.33 0.138 x x x x 0.045 mg/L USEPA 6010B
Lead 0.063 <0.013 <0.013 x x x x <0.013 mg/L USEPA 6010B
Nickel 1.03 0.66 0.521 x x x x 0.314 mg/L USEPA 6010B
Oil &
mg/L USEPA 413.2
Grease 16.8 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0
pH 6.5 6.7 8.8 8.7 9.0 7.7 8.2 8.2 Units USEPA 9040B
TSS 228 19.3 14.0 9.3 <2.5 28.7 6.0 14.0 mg/L APHA 2540 D
Turbidity 129 22.7 0.6 0.4 0.3 1.0 0.7 0.8 NTU USEPA 180.1
Zinc 0.553 <0.004 <0.004 x x x x <0.004 mg/L USEPA 6010B

SUPERNATANT – Compressed Garbage Leachate FOOD (Soy Sauce) Mfr.

SINGAPORE – 2006/ 2007 Johor, MALAYSIA – 2005
Parameter RAW ECR Max. Method
Parameter RAW ECR Max.
In Mg/L Leachate Result Limit Reference In Mg/L Water Result Limit
pH Value 3.8 5.3 6-9 APHA 4500H-98 TD Salts 748 790 --
COD 68,000 25,000 600 APHA 5220-05 TSS 5,041 2.2 100
TSS 3,440 380 400 APHA 2540D-05 COD 21,668 909 100
TD Solids 32,800 19,000 3,000 APHA 2540C-05 BOD 6,373 327 50
Fats , O&G 2,560 380 60 APHA 5520-05 pH 4.4 6.2 5.5-9.0
Fats O&G 38 Nil 10.0
SEWAGE - Domestic Influent Chenai INDIA - 2005
Parameter RAW ECR FOOD (Soft Drink) Mfr.
In PPM Water Result Bandung, INDONESIA - 2006
75 COD > Bio 356 331 100
TD Solids 3,500 140
Volt TSS > Bio 51 12 200
COD 550 32 COD < Bio 10,540 279 100
5.0
BOD 500 13 Amp TSS < Bio 9,402 23 200
O&G 75 Nil FOOD (Chili & Tomato) Mfr.
TSS 75 8 Jawa Rawat, INDONESIA -2006
E.COLI Absent COD < Bio 6,300 2,700 Alum.
FECALCOLIFORM Absent pH < Bio 3.7 6.0 Elec-
Color Red Clear trodes
STREPTOCOCCOCI Negative
TEXTILE Industry EXPLORATION Drill Waters
INDIA, BANGLADESH – 2005-2007 (SCR) Melibur, INDONESIA- 2005
Parameter RAW ECR Method Parameter RAW ECR Max.
Operations In Mg/L Result Result Reference In Mg/L Water Result Limit
TD Salts 2,930 3,100 APHA 2540 COD 615 60 100
Dye Bath TSS 57 4 APHA 2540 Phenol .98 .27 0.5
& Finish COD 413 164 APHA 5220 Ammonia 4.83 2.44 1.0
Mixed BOD 148 78 APHA 5210
Washwaters O&G 270 .41 10.0
Color >250 30 HAZEN Unit pH 7.5 8.7 6-9
pH 9.7 10.8 APHA 4500
Iron 0.31 Nil 5.0
COD 871 98 APHA 5220
Yarn Weaving Manganese 0.086 0.009 2.0
BOD 309 34 APHA 5210
O&G 142 .02 APHA 5520 EXPLORATION Drill Waters
Water Jet Color 150 10 APHA 2120 (SCR) Jambi, INDONESIA 2006 - 2008
pH 5.8 8.6 APHA 4500 COD 375 38 Close Reflux
TD Salts 323 321 APHA 2540 Azide Mod.
BOD 215 15
DYE Bath TSS 267 171 APHA 2540 TSS 2,950 98 Dried at 105
& Finish COD 842 355 APHA 5220
Mixed O&G 577 Nil Soxhlet Extr.
BOD 249 112 APHA 5210
Washwaters Turbidity 1,332 18 Nephelometric
Color >250 60 LOVI Meter
H2S 0.24 0.02 Iodometric
pH 10.3 10.9 APHA 4500
Dyeing COD 713 270 3A X 75V Ammonia 38 4 Titrimetric
Printing Lead 0.73 0.002 AAS
COD 4,923 980 6A X 200V
Post Bio.. COD 98 16 2.5A X 250V pH 8.0 8.2 Elecrometric
TD Salts 494 625 APHA 2540 Color 14,000 500 HAZEN Unit
TSS 20 4 APHA 2540 PRODUCED Waters
TEXTILE (SCR) Duri, INDONESIA - 2008
COD 27 14 APHA 5220
RIVER Feed BOD 9 5 APHA 5210 COD 610 58 100
Water Color 50 20 HAZEN Unit BOD 375 15 50
pH 3.8 4.1 APHA 4500 Phenol 0.63 0.19 0.5
Hardness 30 34 APHA 2340 O&G 156 Nil 10.0
pH 7.5 8.7 6-9
Central Effluent Treatment Plant – SIPCOT – Erode, India
Arsenic 180 Nil 0.1
Effluent COD 728 272 Site Lab
Dye Bath Iron 0.52 Nil 5.0
COD 3,060 1,440 Site Lab
Manganese 0.086 0.009 2.0

TANNERY (Raw Hide) Operation Average %

Erode, INDIA - 2005 Heavy Removed Other Average%
Parameter RAW ECR Metals or Contaminants Removed
In Mg/L Water Result Recovered
Aluminum 99.0 Aldrin P 98.0
E
Collection Tank Effluent Arsenic 96.0 Chloreiviphos S 99.0
Barium 98.0 Cypermethrin T 94.0
I
COD 7,560 2,943 Calcium 98.0 DDT C 99.0
BOD 3,442 1,012 Cadmium 98.0 Diazinon I 99.0
D
Chromium 99.0 Lindane E
99.0
Reverse Osmosis Feed Water Cobalt 62.0 Proptamphos S 99.0
Copper 99.0 Boron 70.0
COD 102 96 Iron 99.0 Cyanide 99.0
BOD 27 17 Lead 97.0 E. Benzene 99.0
Magnesium 98.0 MP-Zylene 98.0
Chromium Recovery by ECR Manganese 83.0 O-Zylene 98.0
Mercury 66.0 Toluene 99.0
Iron Cells 10 Amps 3,603 Total Cr. Molybdenum 80.0 Fluoride 60.0
Alum. Cells 10 Amps 2,370 Total Cr. Nickel 99.0 Nitrate 40.0
TANNERY (Shoe) Operation Vanadium 95.0 Nitrogen TKN 93.0
Zinc 99.0 PCB-Arochlor 82.0
East Java, INDONEISA - 2006
Platinum 83.0 Hydrocarbons 98.0
Parameter RAW ECR Selenium 42.0 Phosphate 98.0
In ppm Water Result Silver 91.0 Potasium 45.0
Tin 89.0 Silicon 99.0
COD < Bio 4,500 1,200
TEXTILE Industry
OTHER APPLICATIONS
Dhaka, BANGLADESH April 2007
Raw ECR Bangladesh Method
Parameters Water Result Discharge Reference
Limits Lagoon and Pit Cleanup
M. Ind. Factory ECR performs reclamation of ground water
TDS 2,840 2,865 2100 Mg/L contaminated with heavy metals, high
pH 8.62 9.54 6-9 molecular weight hydrocarbons and
TSS 60 8 150 Mg/L halogenated hydrocarbons.
Turbidity 670 88 FTU
COD 310 125 200 Mg/L Process & Rinse Waters
U. Group Factory
ECR treats process & rinse waters from
TDS 1,420 1,415 2100 Mg/L
pH 8.31 8.41 6-9 electroplating, computer board & chip
TSS 27 4 150 Mg/L manufactures, paint rinse water, steel
Turbidity 43 25 FTU production, mining industry, automotive,
COD 190 28 200 Mg/L airline and equipment repair & washing.
S. Textile Factory
TDS 750 760 2100 Mg/L Cooling Waters
pH 10.53 9.85 6-9 ECR is used to pre-treat water entering
TSS 83 18 150 Mg/L towers as well as blow down water to
Turbidity 461 29 FTU
remove algae, suspended solids, calcium, and
COD 490 318 200 Mg/L
M. Group Factory magnesium buildup.
TDS 2,765 2,135 2100 Mg/L
pH 8.91 9.05 6-9
Water Pretreatment
TSS 105 27 150 Mg/L ECR has proven effective in removing
Turbidity 172 74 FTU bacteria, silica and TSS prior to subsequent
COD 404 80 200 Mg/L polishing with reverse osmosis, ultra &
S. Denim Washing nano-filtration.
TDS 164 139 2100 Mg/L
pH 6.58 6.68 6-9 Food & Beverage
TSS 417 31 150 Mg/L Meat, Poultry, Fish, - Total plant effluents.
Turbidity 310 36 FTU The ECR can harvest additional protein & fat
COD 808 190 200 Mg/L
while removing FOG and COD.
PAPER RECYCLING – PACKAGING Factory
TDS 926 754 2100 Mg/L Emulsified Oils in Water
pH 6.61 7.55 6-9 ECR removes metals, oils, & dirt, from the
TSS 1,143 7 150 Mg/L exploration waters inherent with oil
Turbidity 636 29 FTU
gathering and processing facilities .
COD 1,112 350 200 Mg/L

ADVANTAGES of ECR DIS-ADVANTAGES of ECR

 ECR gives good, clear, colorless & sometimes odorless water.  Electricity may be too expensive in
 ECR sludge is easy to de-water & is a low sludge producing System. many parts of the world
 ECR systems have no moving parts, thus requiring less maintenance.  ECR will NOT remove Salts
 ECR effluent has less TD Solids contributing to lower water recovery costs. & Mono-valent Ions
 ECR removes the smallest colloidal particles & facilitates faster coagulation