<p>In this study, the removal of Cr(VI) from aqueous solution by electrocoagulation with aluminum anodes was investigated, focusing on the effect of process parameters such as applied potential, initial Cr(VI) and supporting electrolyte (KCl) concentration, and pH. Kinetic experiments were performed for different levels of these variables. The data were applied to several models and found to better fit the pseudo first-order kinetic model. The highest metal removal rate was obtained at 7.5&#xa0;V with 0.0857 lmin⁻¹. Temperature and pH changes over the course of the experiment were examined. A gradual increase in both pH and temperature was observed from the commencement of the experiments. It was also demonstrated that the applied voltage and the quantity of supporting electrolyte were more influential in this regard than other variables. Furthermore, Box-Behnken design (BBD) and response surface methodology (RSM) were employed to statistically analyse the individual and combined effects of voltage, pH, supporting electrolyte concentration and time parameters on metal removal efficiency and energy consumption in detail. The optimal conditions for the maximum removal of Cr(VI) (99.469%) while minimizing energy consumption were predicted to be a pH of 6.365, a voltage of 3.840&#xa0;V, a KCl concentration of 2.524&#xa0;gL⁻¹, and a time of 57.841&#xa0;min, with a high desirability of 0.924.</p> Graphical Abstract <p></p>