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The increasing production of oily wastewater as a by-product of industry has become a major environmental problem. Therefore, this article investigates the removal of mineral oil from oily wastewater by a circulating flow sono-electrocoagulation. The Box–Behnken design was used to study the effects of characteristic electrocoagulation and ultrasonic parameters on mineral oil removal efficiency. A total of 34 different experimental setups were performed at a laboratory scale. A reduced cubic regression model with derived coefficients was developed to describe the mineral oil removal rate. The experimental results show that circulating flow sono-electrocoagulation with iron electrodes can effectively reduce mineral oil by 93.3% under the optimum conditions of 10.948 cycles, a current density of 107.12 A m −2  and a flow rate of 0.468 L s −1 . The experimental observations agreed well with the modeled values, and the model was verified experimentally. Under the optimal conditions, the average operating cost was 0.77 EUR/m 3 .

Application of Box–Behnken design for circulating flow sono-electrocoagulation for oily wastewater treatment