In this paper we describe a novel design of electrocoagulation system for wastewater treatment using sacrificial aluminum electrodes The wastewaters considered were contaminated by a fluorescent penetrant liquid used for non-destructive testing of parts in the aircraft industry and could not be treated satisfactorily by conventional physical chemical or biological processes The new electrochemical system clarified the contaminated rinse water and allowed it to be re-used 4 times The system could reduce 95% of the chemical oxygen demand 99% of color and 99% of turbidity in the discharged wastewater Cost estimates for the process represent an investment-return time for the electrocoagulation system of about 17 weeks (C) 2010 Elsevier Ltd All rights reserved