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Electrocoagulation (EC) is an electrochemical treatment method that removes various pollutants from wastewater. It has grown in popularity over conventional treatment methods, especially in industrial wastewater, due to its high performance and the ability to remove toxic compounds. However, it is crucial to reduce the costs associated with EC for widespread implementation. It is also important to decrease nickel (Ni) concentrations in wastewater to prevent potential health and environmental problems. Therefore, this study investigates Ni removal from synthetic and real wastewater using electrocoagulation. Zinc, as a novel electrode, was used as the sacrificial anode. Several operating conditions were assessed, including current density, initial pH, electrolysis time, and spacing between electrodes. The maximum Ni removal efficiency, after 90\u00a0min, reached 99.9% at a current density of 10\u00a0mA\/cm<jats:sup>2<\/jats:sup> when the pH was 9.2 and the gap distance was 4\u00a0cm. The Ni removal rate reached 94.4% and 94.9% at a 2- and 6-cm spacing, respectively, after 90\u00a0min. Anode morphology, kinetic modeling, electrical energy consumption, and cost analysis were also investigated. The type of corrosion was uniform, which is easily predicted compared to pitting corrosion. The comparison between chemical coagulation and electrocoagulation was also reported. Experimental results indicated that the maximum Ni removal rates reached 99.89% after 90\u00a0min. The optimum spacing between electrodes was 4\u00a0cm, and the optimum current density was 10\u00a0mA\/cm<jats:sup>2<\/jats:sup>. Additionally, the kinetic data were best represented through the second-order Lagergren model. The results demonstrated that the electrocoagulation performance was better than that of chemical coagulation for Ni removal. The maximum electrical energy consumption was 23.79\u00a0KWh\/m<jats:sup>3<\/jats:sup> for Ni removal.<\/jats:p>","DOI":"10.1007\/s11356-022-24101-6","type":"journal-article","created":{"date-parts":[[2022,11,12]],"date-time":"2022-11-12T01:02:31Z","timestamp":1668214951000},"page":"26650-26662","update-policy":"https:\/\/doi.org\/10.1007\/springer_crossmark_policy","source":"Crossref","is-referenced-by-count":56,"title":["Nickel removal from wastewater using electrocoagulation process with zinc electrodes under various operating conditions: performance investigation, mechanism exploration, and cost analysis"],"prefix":"10.1007","volume":"30","author":[{"given":"Omar A.","family":"Shaker","sequence":"first","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-8447-9159","authenticated-orcid":false,"given":"Safwat M.","family":"Safwat","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Minerva E.","family":"Matta","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"297","published-online":{"date-parts":[[2022,11,12]]},"reference":[{"key":"24101_CR1","doi-asserted-by":"publisher","DOI":"10.1016\/j.jwpe.2020.101906","volume":"40","author":"NN Abdulrazzaq","year":"2021","unstructured":"Abdulrazzaq NN, Al-Sabbagh BH, Shanshool HA (2021) Coupling of electrocoagulation and microflotation for the removal of textile dyes from aqueous solutions. 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