Corrugated stainless-steel mesh as a simple engineerable electrode module in bio-electrochemical system: Hydrodynamics and the effects on decolorization performance

[Display omitted] •A cost-effective and engineerable electrode module for BES was developed.•Decolorization significantly increased by designing electrode as the corrugated type.•c-SMEM was found to improve the hydrodynamics condition in BES.•Economic analysis was carried out and compared with conventional anaerobic system. The application of bio-electrochemical system (BESs) is strongly depended on the development of the engineering applicable electrode. Here we described an economical and readily processable electrode module with three-dimensional structure, the corrugated stainless-steel mesh electrode module (c-SMEM). This novel developed electrode module was demonstrated to provide a good hydrodynamic characteristic and significantly enhanced the decolorization performance of the BES when serving for treating azo dye (acid orange 7, AO7) containing wastewater. Compared to the conventional planar electrodes module (p-SMEM), c-SMEM was found to prolong the mean residence time (MRTθ) of AO7 and change the flow pattern closer to the plug flow. As a result, the maximum enhancement of the volumetric decolorization rate (vDR) can reach to 255%, even when the c-SMEM and p-SMEM have the same electrode surface area. In addition, a techno-economic analysis model was established to elucidated the effects of the decolorization performance and the material cost on the initial capital cost, which revealed the BES with c-SMEM could be economically comparable to or even better than the traditional bio-decolorization technologies. These results suggest c-SMEM holds great potential for engineering application, which may help paving the way of applying BES at large-scale.