Abstract:　The　molten　salt　electrochemical　method　is　an　efficient　one-step　process　to　extract　tungsten　from　tungsten　carbide　(WC).　Owing　to　the　limitation　of　molten　salt　electrochemical　experiments　and　the　number　of　data　points,　determining　the　optimal　process　conditions　is　challenging.　In　addition,　the　mechanism　that　affects　the　current　efficiency　is　difficult　to　obtain　intuitively.　In　this　study,　simulations　of　tungsten　carbide　anode　electrolysis　were　obtained　using　the　COMSOL　Multiphysics　5.3,　and　the　results　were　compared　to　the　dissolution　experiment　of　tungsten　carbide　with　varying　content　of　sodium　tungstate (Fig.　1).　The　experimental　data　fitted　well　with　the　theoretical　current　efficiency　of　75%.　At　concentrations　below　0.5　wt%　of　sodium　tungstate,　the　anode　dissolution　showed　a　linear　relationship　against　the　concentration　of　sodium　tungstate.　At　a　constant　concentration　of　sodium　tungstate,　the　anodic　dissolution　decreased　with　increasing　immersion　depth,　consistent　with　the　variation　of　cell　voltage　difference　before　and　after　electrolysis.　The　optimal　immersion　depth　and　effective　area　of　the　anode　estimated　by　simulations　were　2.5 mm　and　0.465　mm2,　respectively (Fig.　2).　Under　the　optimum　electrolysis　conditions　simulated　by　COMSOL,　the　nano　tungsten　powder　was　obtained.　Graphic　abstract:　[Figure　not　available:　see　fulltext.]　©　2021,　The　Author(s),　under　exclusive　licence　to　Springer　Nature　B.V.　part　of　Springer　Nature.