Smart Skid-Mounted Electrocoagulation & DAF System: Turning Industrial Wastewater into Value | YASA ET
- kunyapak
- Nov 10, 2025
- 3 min read
Updated: Nov 18, 2025
Content
1. Introduction: Why EC–DAF Matters
Industrial wastewater is becoming increasingly complex, with contaminants such as oil & grease, COD, dyes, surfactants, heavy metals, and suspended solids. Meeting stricter discharge regulations while reducing operational costs has become a major challenge for factories worldwide.
To address this, YASA ET has developed a Smart Skid-Mounted Electrocoagulation (EC) + Dissolved Air Flotation (DAF) system, designed to simplify treatment, improve removal efficiency, and reduce chemical consumption.
Built with PP corrosion-resistant materials and controlled with Siemens PLC automation, the system provides a compact, modular, plug-and-play treatment solution suitable for pilot trials and full-scale operations.
2. How the EC–DAF System Works
2.1 Electrocoagulation (EC) Stage
Wastewater enters the EC reactor, where electrical current and metal electrodes (aluminum or iron) destabilize contaminants. Particles form larger flocs as a result of:
Coagulation
Electrochemical oxidation
Adsorption & aggregation
Real-time pH and conductivity sensors ensure ideal reaction conditions. Floc formation usually takes ~40 minutes, after which the mixture flows to the next stage.
📚Studies confirm that EC effectively removes COD, dyes, heavy metals, microplastics, and oils through simultaneous coagulation and oxidation. (Akyol 2023 – ScienceDirect; Bhattacharya 2021 – RSC; Al-Qodah 2023 – MDPI Water)
The diagram illustrates the complete water path from raw wastewater feeding, EC reaction, settling clarification, DAF flotation, and final treated-water collection.
2.2 Settling & DAF Separation Stage
The EC-treated water flows into a three-chamber clarification tank:
• DAF Chamber: Microbubbles attach to fine flocs and float them.• Settling Zone: Heavy solids sink naturally.• Clear Water Chamber: Produces clarified effluent.
Lamella plates dramatically improve solids–liquid separation, while PAD dosing at the DAF inlet enhances removal of fine particles.
📚 Research confirms DAF is one of the most effective post-treatment technologies for removing suspended solids and oils, especially when coupled with EC pretreatment. (Silva 2022 – ResearchGate Review)
3. Key Advantages of EC–DAF Technology
Compact Modular Design
EC + Settling + DAF integrated into one skid-mounted system.
High Removal Efficiency
Up to 95% oil & grease, 90%+ TSS, and major COD reduction.
Lower Chemical Usage
Reduces PAC/PAM consumption compared to traditional coagulation.
Energy Efficient
Operates at very low voltage (0–12 V).
Automatic Polarity Reversal
Prevents electrode passivation and extends lifespan.
Fast Installation
Plug-and-play design — no civil work required.
4. Industrial Applications
YASA ET’s EC–DAF systems are widely used for:
Food & beverage wastewater
Textile dyeing and printing• Petrochemical & refinery effluent
Metal finishing & plating wastewater
Industrial or municipal ZLD pretreatment
📚 EC–DAF hybrids achieve over 90% pollutant removal across diverse wastewater types. (Ebrahimi 2022 – MDPI Water 15(8))
5. YASA ET Skid-Mounted EC–DAF System
The YASA ET system includes:
Submersible feed pump (1–2 m³/h)
Dual-chamber EC reactor• Three-stage settling + DAF separation tank
PAC/PAD dosing systems• Siemens PLC + touchscreen HMI
Recirculation & air injection system
PP corrosion-resistant structure
The entire system arrives fully assembled.
Just connect → power → start treatment.
6. System Design & Technical Features
Intelligent PLC Automation
A Siemens PLC manages:
Voltage & current control
pH / EC sensor feedback
Flow & recirculation timing• Automatic polarity reversal
Data logging & alarms
Remote monitoring is available via Modbus or cloud.
Materials
PP reactor tanks
Stainless steel fittings
Anti-corrosion internal components
Safety & Reliability
Over-current protection
Interlock alarms
Auto shut-off programming
7. Example Performance & Treatment Results
Typical treatment reductions:
Oil & Grease: >95%
TSS: >90%• COD: 50–80% (depending on wastewater composition)
Color / dyes: Significant reduction
Metals: Strong adsorption by EC flocs
Suitable for direct discharge polishing, RO pretreatment, or ZLD evaporator feed.
8. Environmental and Economic Benefits
Less Sludge, Lower Disposal Cost
EC produces denser and dryer sludge compared to chemical coagulation.
Chemical Savings
Less coagulant and co-dosing required.
Energy Savings
Low-voltage operation reduces electricity cost.
Supports Circular Economy
Cleaner water, reduced waste, and improved resource efficiency.
9. FAQs
1. What is the main benefit of combining EC with DAF?
High removal efficiency for both heavy solids and fine colloids.
2. Does the system require high maintenance?
No. Automatic polarity reversal reduces cleaning frequency.
3. Can the system be scaled up?
Yes, available from lab-scale to 100 m³/h industrial units.
4. What industries typically use EC–DAF?
Textile, plating, food processing, petrochemical, manufacturing, etc.
5. Does EC–DAF help with ZLD?
Yes, it is commonly used as pretreatment before RO or evaporators.
For the right treatment system, you need the right expertise.
For more information about our zero liquid discharge systems, kindly get in touch at:
🌐 www.yasa.ltd（EN）
🌐 www.yashahuanjing.cn (中文）
📱 +86 136 3643 1077
YASA ET official online store > click here
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