Multiphysics Simulation Research Articles

Flow field design and visualization for flow-through type aqueous organic redox flow batteries

Aqueous organic redox flow batteries (AORFBs), which exploit the reversible redox reactions of water-soluble organic electrolytes to store electricity, have emerged as a promising electrochemical energy storage technology. Organic electrolytes possess fast electron-transfer rates that are two or three orders of magnitude faster than those of their inorganic or organometallic counterparts; therefore, their performance at the electrode is limited by mass transport. Direct adoption of conventional cell stacks with flow fields designed for inorganic electrolytes may compromise AORFB performance owing to severe cell polarization. Here, we report the design of a flow field for flow-through type AORFBs based on three-dimensional multiphysics simulation, to realize the uniform distribution of electrolyte flow and flow enhancements within a porous electrode. The electrolyte flow is visualized by operando imaging. Our results show that multistep distributive flow channels at the inlet and point-contact blocks at the outlet are crucial geometrical merits of the flow field, significantly reducing local concentration overpotentials. The prototype pH-neutral TEMPTMA/MV cell at 1.5 M assembled with the optimized flow field exhibits a peak power density of 267.3 mW cm-2. The flow field design enables charging of the cell at current densities up to 300 mA cm-2, which is unachievable with the conventional serpentine flow field, where immediate voltage cutoff of the cell occurs. Our results highlight the importance of AORFB cell stack engineering and provide a method to visualize electrolyte flow, which will be appealing to the field of aqueous flow batteries.

Active Sites Regulation and Mass Production of a Hierarchically Porous Fe-N-C Catalyst for Zinc-Air Batteries.

Although the iron-nitrogen-carbon (Fe-N-C) catalyst has great potential in zinc-air batteries (ZABs), the insufficient performance and low production of the Fe-N-C catalyst are still the key factors that greatly limit the commercial application. In this study, first, a simple dual melt-salt template method is developed to prepare the hierarchically porous HPFe-N-C catalyst with abundant highly stable Fe-pyridinic-N sites. Then, HPFe-N-C and Fe-phenanthroline are mixed and heated for the mass production of THPFe-N-C with rich highly active Fe-pyrrolic-N sites. Under the synergistic effect of the different active sites, THPFe-N-C exhibits better activity and stability of oxygen reduction reaction (ORR) than Pt/C. Density functional theory is utilized to reveal the changing of the free energy for the ORR process of active sites. COMSOL multiphysics simulations are used to prove that the hierarchically porous THPFe-N-C is beneficial to the O2 mass-transfer process. Therefore, THPFe-N-C shows a better discharge performance and peak power density than Pt/C in the ZABs.

Enhancing Scalability and Consistency in Pulsed Electric Field Processing of Microalgae: Integrating Single-Cell Suspension Rheology and Multiphysics Simulation

Emerging extraction technologies such as microsecond pulsed electric field (μsPEF) offer an energy-efficient and gentle method for downstream processing of single cells. However, attaining consistent processing outcomes in continuous PEF systems across different scales is challenging due to variations in cell residence times caused by cell concentration and flow-dependent rheological behavior. This study employed COMSOL Multiphysics® simulations to model rheological changes in high-density heterotrophically grown Auxenochlorella protothecoides microalgae suspensions. The model was designed to precisely estimate residence times for consistent μsPEF treatment and increased processing capacity at high flow rates and cell concentrations. Implementing the simulated residence times into experimental validations achieved consistent treatment outcomes, resulting in 86 ± 4% of cells being permeabilized and increased processing capacity from 21 to 300 mL min-1. Higher cell concentrations led to increased energy input and decreased protein extraction yields, indicating complex underlying permeabilization and diffusion processes during and after treatment. This work advances scalable and consistent μsPEF technology for single-cell downstream processing by applying cell suspension rheology and residence time simulations.

Simulating hydrogen-controlled crack growth kinetics in Al-alloys using a coupled chemo-mechanical phase-field damage model

Environmentally Assisted Cracking (EAC) of 7xxx series aluminium alloys involves interactions between multiple physical phenomena, which ultimately influence the in-service life of critical components. In this work, we present a new model to study EAC in 7xxx series alloys, which is implemented in the multiphysics simulation framework, DAMASK. The chemo-mechanical model couples crack tip hydrogen generation, resulting from surface oxidation, and transport, with crystal-plasticity-governed intergranular crack propagation, through the microstructural trapping of hydrogen at dislocations, grain boundaries (GB), and crack tip stress fields. Large-scale simulations with realistic grain structures have been performed to provide novel insight into the dominant rate-controlling processes associated with intergranular EAC in 7xxx series aluminium alloys. The model was able to reproduce experimentally measured crack velocities under different loading conditions. Parametric studies indicate that, in addition to the GB network morphology, the crack growth rate was controlled by hydrogen generation at the crack tip with long-range diffusion having negligible influence. Additionally, the total hydrogen generated through crack tip oxidation appears to be more significant than the peak generation rate.

Minimum solar tracking system for a Fresnel lens-based LCPV

The aim of the work is to study a low concentration photovoltaic (LCPV) system based on a Fresnel lens with a plano-concave lens and reflective surfaces. The proposed system is aimed at working with single-junction polycrystalline silicon solar cells with a wider reception angle which reduces the energy consumption of the solar tracking system. A software for multiphysics simulations COMSOL was used to simulate the proposed LCPV system with a maximum concentration ratio (6.5), and calculations were carried out to determine the relative position of the lenses from the solar cell. The proposed LCPV system achieves higher acceptance angle (±9.1°) and concentration acceptance angle product (0.447) compared to the conventional LCPV system (±3.1°, 0.153). Calculations of the power consumption of a dual-axis solar tracker using the proposed optical system show a reduction in power consumption of 21% in azimuth, 37% in altitude, and 27% overall when using the proposed optical system.

Mathematical modeling and simulations using software like MATLAB, COMSOL and Python

This study explores the application of MATLAB, COMSOL, and Python in mathematical modeling and simulation within precision engineering. These tools are analyzed for their strengths in handling various engineering challenges, from control systems to multiphysics simulations and custom algorithm development. The study also investigates the role of artificial intelligence (AI), in supporting mathematical modeling tasks by automating coding, providing concept explanations, and aiding model structuring. By comparing computational performance, accuracy, and usability, the research aims to identify the best-suited software for different simulation types, such as thermal-fluid dynamics and structural analysis. The findings underscore the significance of choosing appropriate software for optimizing computational resources, validating models, and achieving reliable, efficient simulations. This study contributes practical guidelines for bridging the gap between theoretical models and practical applications, enhancing productivity, and fostering innovation in precision engineering.

Experimental and computational studies on hot cracking in single laser tracks of aluminium alloy AA2024 and related implications for laser powder bed fusion

Laser powder bed fusion of high-strength aluminium alloys remains challenging due to the formation of hot cracks during the printing process. Hot cracking is a complex phenomenon involving a complex thermo-mechanical and metallurgical interplay. Such relationship needs to be fully understood to reap the benefits of advanced laser modulation (temporal and spatial) capabilities, now becoming available in PBF-LB. To this end, we explore the formation of hot cracks in single tracks produced using a simple spatial–temporal laser modulation characterised by laser pulses of various distance. The formation of cracks is then rationalised by physical and numerical modelling using multi-physics CFD simulation. We demonstrate that the area of the mushy zone at the back of the moving melt pool, dynamically contracts and expands according to the laser temporal regimes and find maxima in correspondence to the largest laser pulse distance and the time steps between exposures. By then analysing in detail in the crack observed in the printed parts fabricated with the same laser modulation, it is possible to conclude that the mechanisms leading to hot cracks in these specimens is analogous. In turn, the insights on single tracks can be extended, for the most part, to the case of bulk specimens. Nevertheless, printed specimens appear to be more sensitive to the erratic movement of the melt pool, due to the presence of a larger number of highly energetical grain boundaries and unintended microstructural defects (voids and inclusions), from which cracks can nucleate.Graphical

Theoretical study on electrochemical and thermal behavior of GNP incorporated anode materials for lithium-ion batteries

In this paper, a theoretical investigation of the electrical and thermal performance of lithium-ion batteries employing an unexplored graphene nanoplatelets (GNP) incorporated lithium titanate (LTO-GNP) anode and lithium manganese oxide cathode is demonstrated by using the COMSOL Multiphysics modeling and simulation. The GNP proportions in the LTO active material matrix are varied from 0 to 3 wt%, to assess the improvements in cell potential, state of charge (SOC), variation in internal temperature, discharging capacity, and battery power density across four selected electrodes. The simulation results have indicated the positive effects of increasing the anode’s GNP concentration on the battery performance, alongside temperature-dependent open-circuit voltage (OCV) and SOC outputs of the battery. The analysis of the effects of thermal conductivity on heat accumulation and dissipation within the battery has indicated that the anode with 3 wt% of GNP consistently performed superior to the other electrodes by providing uniform temperature distribution and enhanced electrical performance by promoting better discharge capacity and power density. The LTO anode with 3 wt% GNP has shown 0.2V more cell potential and also has 12.5% improved thermal conductivity when compared to LTO anode without GNP, contributing to better heat distribution inside the battery. The simulation also emphasized the importance of optimal GNP loading in the Li-ion battery anode to attain more uniform temperature distribution with improved battery health and efficiency.

Validity of Thermal Simulation Models for Different Laser Beam Shapes in Bead-on-Plate Melting

AbstractComputational models that predict melt pool shapes and temperature evolution in laser-based powder bed fusion of metals (PBF-LB/M) can range from simple thermal simulation models to more advanced models that incorporate more detailed physics of the process. While advanced models can accurately predict thermal fields and melt pool fluid dynamics, they are computationally more expensive and, thus, less suited for part-scale simulations or numerical optimization, where repeated model evaluations are necessary. On the other hand, thermal simulations are computationally efficient and attractive for their simplicity, but their accuracy is mainly limited to conduction-dominated processes. Moreover, the conduction model’s validity range is not fully understood for non-Gaussian laser beam shapes. This paper demonstrates that predictions of melt pool depth and width carried out by a heat conduction model are accurate to within 20 % for all investigated laser profiles, provided that the simulated maximum temperature does not exceed a certain threshold value for stainless steel 316L. This is established by thoroughly investigating the validity range of the heat conduction model through comparisons with over 200 single-track experiments on bare plates. The temperature predictions from the model are compared with multi-physics simulations using smoothed particle hydrodynamics (SPH). Through detailed analysis and validation for three laser beam shapes, this contribution provides valuable insights into the accuracy and applicability of heat conduction models in bead-on-plate melting simulations and offers a path to optimize process parameters, such as laser beam shape, scanning strategy, and other processes for diverse applications aimed at PBF-LB/M.

Multi-objective optimization design and multi-physics simulation analysis of a novel magnetorheological fluid-elastomer damper

Aiming at the problem of the suspension isolator not being able to adjust the damping, magnetorheological damping technology was introduced based on the traditional rubber passive suspension. A magnetorheological (MR) fluid damper was designed inside the rubber suspension and connected with the rubber structure to form a magnetorheological fluid-elastomer (MRFE) damper. The design principle of the MR damper was described. The principle prototype of the initial MRFE damper was designed, and the mechanical properties of the damper were tested through experiments. Taking the damping force, dynamic adjustable range and power as the optimization objectives, the structure of the MR damper was optimized using the non-dominated sorting genetic algorithm II (NSGA-II). The Pareto optimal solution set of MR damper parameters was obtained, and the structural parameters of the MR damper were determined based on the principle of minimum response time. A multi-physics field simulation model of the optimal damper was established to analyze the dynamic performance of the MR damper. The principle prototype of the optimal MRFE damper was obtained, and the optimal MR damper increased the damping force by 63.1% and the dynamic adjustable range by 104.9% compared with the initial MR damper, while the optimal MRFE damper increased the damping force by 9.27% and the dynamic adjustable range by 8.85% compared with the initial MRFE damper. The design results meet the requirements, and the proposed optimization method can provide a theoretical basis for the optimal design of related vibration-damping equipment.

Multiphysics Simulation of Continuous Liquid Interface Production (CLIP) 3D Printing Technology

Abstract This study explores the advancements of 3D printing through Continuous Liquid Interface Production (CLIP), which has achieved a remarkable 100-fold increase in print speed over conventional stereolithography. CLIP’s rapid printing is enabled by an oxygen inhibition layer above the resin-vat window, initiating photopolymerization above the deadzone for faster resin flow. Despite CLIP’s notable speed advantage, it struggles with artifacts arising from non-optimal print cofigurations. Our research addresses this challenge by developing a novel multiphysics simulation tool. In order to evaluate the effects of various parameters, this study introduces a 2D-CLIP multiphysics simulation tool integrating optical and chemical models. The simulation tool employs a MATLAB-PDE solver that incorporates multiphysics equations to forecast deadzone thickness and cured dimensions at various print settings. This approach allows for a comprehensive understanding of the CLIP process and its variables. The simulation tool effectively predicts key parameters, aiding in the fine-tuning of the printing process. It significantly reduces experimental costs and time while enhancing the precision of CLIP 3D printing. The tool’s predictions are instrumental in optimizing print parameters, thereby mitigating the prevalent artifacts in printed objects. This research contributes a pioneering simulation tool for CLIP 3D printing, addressing the critical gap in optimizing print configurations. Its innovative approach in integrating multiphysics models within a simulation framework offers a valuable asset in advancing the capabilities of high-speed 3D printing technologies.

Water-salt transport modeling and sulfate erosion mechanisms in cultural heritage under microclimate

The microclimate of the environment influences the characteristics of salt erosion in historical cultural heritage, determining the pattern of salt weathering and the mechanism of salt-action. The study focuses on the influence of cultural heritage microclimate on salt weathering, and the study aims to understand the weathering mechanism by combining the theory of crystalline weathering with temperature and humidity variation. The study comprised immersing sandstone from the Yungang Grottoes, a World Heritage Site, in a sulfate salt solution and simulation of salt deterioration under on-site cyclic variable temperature and humidity conditions. The article designs the accumulation of salt crystallization at the sandstone surface under the effect of salt evaporation and visualizes the water-salt migration and crystallization process by ion chromatography (IC), microelectrode, and hyperspectral techniques. The corresponding types of sulfate deterioration under different weathering simulation conditions are investigated to probe the mechanism behind different weathering patterns. In the first part, we construct a water-salt migration test, combining hyperspectral techniques and microelectrodes to visualize the weathering patterns, compositional characteristics, and spatial and temporal changes of water-salt transport based on Fick's law to establish a mathematical model and simulate it in COMSOL multi-physics field simulation software. Subsequently, tests were carried out on sandstone with sulfate solution at variable temperatures and humidity levels to simulate the process of salt weathering. The results demonstrated that different salt solutions, such as Na2SO4 and MgSO4, lead to the dissolution of clay minerals. At the same time, crystallization disrupts the sandstone structure, causing degradation of its physico-mechanical properties after several weathering cycles, and there are significant differences in the salt crystallization patterns at different temperatures and after cycling at different humidities.

A sustainable waveguide-based design strategy for improving the energy efficiency of microwave hybrid heating systems: A combined theoretical and multi-physics simulation approach

The microwave hybrid heating (MHH) based processing has emerged as energy-efficient and productive manufacturing process. The efficiency of MHH depends upon the ability of waveguide system to transmit the electromagnetic radiation with minimal loss. Thus to improve the efficiency of MHH it is of paramount importance to understand the potential of waveguide systems. In the present work, the influence of different waveguide systems, their positioning, and different modes of operation on MHH efficiency were studied via theoretical and simulation investigations followed by experimental validation. Based on the study, the optimum waveguide system was identified as WR430. To assess the efficiency and effectiveness of the waveguide positioning on MHH, 12 different locations were considered, and the optimum location was identified as (+35, −35), with a maximum microwave utilization efficiency of 44.5 %. Subsequently, the simulation model (1049 °C) was validated using experimental data (1017 °C) with an error of less than 10 %. Also, MHH is sensitive to different waveguide operating modes, SiC susceptor positioning and microwave power. A microwave cavity operating with two waveguides on both sides is found to provide optimum results in terms of heating uniformity, electric field distribution, and microwave energy absorption. The SiC susceptor positioned at the centre of the alumina refractory yields maximum heat evolution of 1020 °C. In addition, as the microwave power grows, the temperature differential also increases, implying thermal heterogeneity inside the SiC susceptor. Thus, low microwave power is identified for improved thermal uniformity and energy efficiency, while high power is proven for rapid differential microwave heating.

Characterization of Particle Size Effects on Sintering Shrinkage and Porosity in Stainless Steel Metal Injection Molding Using Multi-Physics Simulation

Characterization of Particle Size Effects on Sintering Shrinkage and Porosity in Stainless Steel Metal Injection Molding Using Multi-Physics Simulation

Aligned Hollow Silicon Nanorods Containing Ionic Liquid Enhanced Solid Polymer Electrolytes with Superior Cycling and Rate Performance.

The low lithium-ion conductivity of polyethylene oxide (PEO)-based polymer electrolytes limits their application in solid-state lithium batteries and related fields. Here, ionic liquids (ILs) are injected into hollow silicon nanorods (HSNRs) to prepare a composite solid polymer electrolyte (CSPE) with aligned HSNRs containing ILs (F-ILs@HSNRs). Applying a magnetic field promoted uniform dispersion and orientation of F-ILs@HSNRs in CSPE. The addition of F-ILs@HSNRs reduced PEO crystallinity and formed Li+ transport pathways at the F-ILs@HSNRs/PEO interface. Calculations and multi-physics simulations reveal that ILs within F-ILs@HSNRs contribute most to lithium-ion conduction, followed by the F-ILs@HSNRs/PEO interface. When F-ILs@HSNRs are arranged perpendicular to the electrodes, the CSPE exhibits the shortest Li+ migration pathways, resulting in stable and efficient lithium-ion conduction. The conductivity (2.14 × 10-4 S cm-1) and lithium-ion migration number tLi+ (0.307) are the highest, being 125 times and 184% higher, respectively, than those of PEO-LiTFSI, when compared to CSPEs with randomly arranged or parallel-aligned F-ILs@HSNRs. Furthermore, Li|CSPE|Li batteries and LiFePO4|CSPE|Li batteries display stable cycling for over 2000h, with coulombic efficiency approaching 100%. Excellent electrochemical reversibility is also confirmed in the rate performance test.

Constructing 3D Crosslinked Macromolecular Networks as a Highly Efficient Interface Layer for Ultra-Stable Zn Metal Anodes.

Aqueous zinc ion batteries (AZIBs) are experiencing rapid development due to their high theoretical capacity, abundant zinc resources, and intrinsic safety. However, the progress of AZIBs is hindered by uncontrollable parasitic reactions and excessive dendrite growth, which compromise the durability and effective utilization of zinc metal anodes. To address these challenges, the study has constructed a 3D crosslinked macromolecular network composed of zinc ion-bonded potato starch (StZ) as an interface layer on Zn foil (StZ-Zn) to inhibit hydrogen evolution, regulate Zn2+ flux, and ensure uniform Zn deposition. Density functional theory calculations, molecular dynamics simulations, COMSOL Multiphysics simulations, and in situ Raman spectra demonstrate that the 3D StZ interface layer facilitates Zn2+ desolvation by restructuring the solvation shells. This process reduces the concentration of H2O at the anode, thereby inhibiting the hydrogen evolution reaction. Consequently, Zn2+ transport is more efficient, promoting a homogeneous Zn2+ flux and enabling dendrite-free Zn deposition. As a result, StZ-Zn||StZ-Zn symmetric cell delivers a superb lifespan of 4800 h at the current density of 5 mA cm-2, and the corresponding cumulative capacity is as high as 12000 mAh cm-2. Notably, StZ-Zn||NaV3O8·1.5H2O full cell can stably operate for 2500 cycles at 5 A g-1 with an outstanding capacity retention of 92%.

Multiphysics simulation of liposome release from hydrogels for cavity filling following patient-specific breast tumor surgery

Several studies have recommended the use of hydrogels for localized targeted delivery of chemotherapeutic drugs following tumor removal surgery. This approach aims to both fill the cavity and prevent cancer recurrence. The use of Multiphysics-based simulation emerges as a valuable strategy for minimizing experimental work, providing detailed insights into how drug release occurs in the tissue, and enabling the optimization of the design.In this study, we introduced a mathematical model, utilizing experimental data, to investigate the transport of liposomes carrying MZ1 from a thermosensitive hydrogel and their impact on the viability of breast cancer cells. The proposed comprehensive model considers not just the transport within the interstitial tissue, represented as a porous medium, but also the uptake by cells and its influence on cell viability, along with the potential lymphatic drainage.The six real patient-specific tumor shapes extracted from MRI scans were used to investigate how the size and form of the tumor can modify the transport pattern. The computational results revealed that the concentration of liposomes in the tissue is significantly influenced by their release from the hydrogel, which proved to be the limiting step. Liposome concentrations of approximately 0.1 % weight were found to be sufficient in ensuring minimal cell survival in the vicinity of the tumor.

A consistent, volume preserving, and adaptive mesh refinement-based framework for modeling non-isothermal gas–liquid–solid flows with phase change

This work expands on our recently introduced low Mach enthalpy method (Thirumalaisamy and Bhalla 2023) for simulating the melting and solidification of a phase change material (PCM) alongside (or without) an ambient gas phase. The method captures PCM’s volume change (shrinkage or expansion) by accounting for density change-induced flows. We present several improvements to the original work. First, we introduce consistent time integration schemes for the mass, momentum, and enthalpy equations, which enhance the method stability. Demonstrating the effectiveness of this scheme, we show that a system free of external forces and heat sources can conserve its initial mass, momentum, enthalpy, and phase composition. This allows the system to transition from a non-isothermal, non-equilibrium, phase-changing state to an isothermal, equilibrium state without exhibiting unrealistic behavior. Furthermore, we show that the low Mach enthalpy method accurately simulates thermocapillary flows without introducing spurious phase changes. To reduce computational costs, we solve the governing equations on adaptively refined grids. We investigate two cell tagging/untagging criteria and find that a gradient-based approach is more effective. This approach ensures that the moving thin mushy region is always captured at fine grid levels, even when it temporarily falls within a subgrid level. We propose an analytical model to validate advanced computational fluid dynamics (CFD) codes used to simulate metal manufacturing processes (welding, 3D printing). These processes involve a heat source (like a laser) melting metal or its alloy in the presence of an ambient (inert) gas. Traditionally, studies relied on artificially manipulating material properties to match complex experiments for validation purposes. Leveraging the analytical solution to the Stefan problem with a density jump, this model offers a straightforward approach to validating multiphysics simulations involving heat sources and phase change phenomena in three-phase flows. Lastly, we demonstrate the practical utility of the method in modeling porosity defects (gas bubble trapping) during metal solidification. A field extension technique is used to accurately apply surface tension forces in a three-phase flow situation. This is where part of the bubble surface is trapped within the (moving) solidification front.

Electromagnetic-thermal multi-physics coupling simulation of cable joints: considering contact resistance and typical defects

As the “artery” of the urban power grid, high-voltage cables and their operating status are directly related to grid safety. Cable joint is a weak part of cable line prone to defects, leading to cable failure and jeopardizing the power supply reliability. This study constructs a three-dimensional electromagnetic-thermal multi-physics coupling model of cable joint for the analysis of contact resistance and typical insulation defects. Using an equivalent conductivity model, the thermal loss and temperature distribution of the joint were investigated under different contact coefficients. Subsequently, models for air-gap defect and water tree defect in cable joints were established to simulate the temperature and electric field distribution under these conditions. The simulation results indicate that, at an ambient temperature of 25°C, the contact resistance of a 110 kV high-voltage AC cable joint significantly increases the loss density, raising the joint temperature much higher than cable body, while not altering the temperature gradient distribution. Small air-gap has minimal impact on the temperature distribution of joint insulation but causes significant electric field distortion up to 8 kV/mm. Water tree defect considerably affects both temperature and electric field, causing a 20°C temperature rise and a 30 kV/mm electric field distortion. This research reveals the strong influence of contact resistance and water tree defect on cable joints, quantifying the resulting hazards like loss increase, temperature rise and electric field distortion.

Peroxymonosulfate-based electrochemical advanced oxidation for pollutant degradation: Roles of Co-phase regulation and electro-induced polarized particle electrodes

Peroxymonosulfate (PMS)-based three dimension-electrochemical advanced oxidation processes (3D-EAOPs) have received increasing attention, but the precise impact of electric field (EF) on particle electrodes (PEs) and integrated system remains poorly understood. This study presented the critical role of EF-induced polarized PEs in the effective activation of PMS and dissolved oxygen, and the subsequent enhancement of overall pollutant remediation. The Co, N-doped bio-polyporphyrin-derived activated carbon (Co-NC@PPAC) PEs were prepared by in-situ growth of zeolitic imidazolate frameworks-67 (ZIF-67) on vanillin-based polyporphyrin followed by pyrolysis. The synergistic effect between the electrochemical catalytic and Co-NC@PPAC catalytic processes in 3D-EF/Co-NC@PPAC/PMS system achieved an enhanced activity for nitenpyram (NTP) degradation, attaining 96.9 % removal rate within 60 min. Mechanistic studies confirmed that singlet oxygen (1O2) produced from the activation of PMS and dissolved oxygen in the cathodic chamber was the dominant reactive oxygen species (ROS) for pollutant degradation. Theoretical calculation results showed that the polarization of PEs with tunable Co-phase could subtly regulate the adsorption and cleavage of PMS, as well as the activation of dissolved oxygen, which resulted in different NTP degradation mechanism. COMSOL Multiphysics simulation confirmed that the ROS involved in NTP degradation mainly originated from the activation of PMS and dissolved oxygen. This study highlighted a promising approach to construct highly cost-effective electrochemical treatment system and proposed a possible mechanism for 3D-EF/PEs/PMS electrochemical process.