Formation Of Powders Research Articles

Black powder and mineral deposits in the LPG production and processing line: Analytical study and formation mechanisms

The accumulation of mineral deposits such as black powder causes severe impacts throughout the gas production and transport process. The phenomenon takes place from gas wells to LNG/LPG treatment plants and terminals. The complexity lies in understanding the mechanisms by which these materials are formed in random quantities, as well as their varied nature. The aim of this study is to monitor black powder and other mineral deposits formation in a chain of gas production and processing situated in the south of Algeria and unravel their root causes. To that extent, an analytical study was carried out on four samples of both mineral deposits and black powder taken from an LPG processing and production unit. The adopted analytical approach included an exploration of the textural and structural properties. It also involves a composition characterizations related to the content of metallic elements, moisture, organic and mineral matter. The particle distribution is also determined. The analytical study was conducted using gravimetric determination, XRD, XRF, SEM/EDX and Raman spectroscopy. Particle distribution was given by Laser granulometry technique. The results of the DRX/FRX and EDX characterization primarily revealed that the samples contain a variety of mineral components such as iron oxides; magnetite Fe3O4 and hematite Fe2O3, iron oxy-hydroxide FeO(OH), iron sulphide FeS2, calcite CaCO3, SiO2 and halite NaCl. The presence distribution of these components depends on the location of the sample in gas line. Granulometry study shows that black powder contamination can be spread over a wide spectrum of particle sizes ranging from 1.51 µm to 678.50 µm. This study has allowed to elucidate the nature and distribution of particles deposited at different positions in the LPG production chain and to propose probable mechanisms for their formation.

Spray Drying of Inca Peanut Meal Protein Hydrolysate to Produce Protein Powder Drink Mix

The optimal conditions (maltodextrin concentration and inlet air temperature) for spray drying Inca peanut meal protein hydrolysate (IMPH) were determined. The maltodextrin concentration was varied at 5, 10 and 15 % by weight, and inlet air temperature was varied at 150, 160 and 170 °C. The IMPH was subjected to spray drying, where the feed solution was atomized into fine droplets and exposed to a hot air stream, leading to rapid drying and the formation of powder. The moisture, protein, yield, water activity and water solubility index (WSI) of IMPH powder were analyzed. The optimal condition for spray drying IMPH powder utilized 10 % maltodextrin and an inlet air temperature of 160 °C. Under these conditions, the moisture, protein, yield and WSI of IMPH powder were 2.93, 36.93, 38.95 and 99.59 %, respectively, while water activity was 0.41. IMPH powder particles were spherical and non-agglomerate. Inca peanut meal protein powder drink mix (IMPD) with cocoa flavor was the most acceptable. The IMPD with cocoa flavor could be promoted as a high protein and high dietary fiber product. It could be kept at 35 ± 2 °C for 12 weeks, whilst retaining good microbiological properties. HIGHLIGHTS The optimal conditions for spray drying Inca peanut meal protein hydrolysate (IMPH) were determined to be 10% maltodextrin and an inlet air temperature of 160 °C. This resulted in high yield, protein content, and water solubility, while keeping moisture and water activity low. IMPH powder had spherical, non-agglomerated particles, and cocoa-flavored Inca peanut protein powder drink mix (IMPD) was the most preferred in sensory evaluations. The IMPD with cocoa flavor was identified as a high-protein, high-dietary-fiber product, suitable for storage at 35 °C for up to 12 weeks while maintaining good microbiological quality. The study highlights the nutritional benefits of the cocoa-flavored IMPD, which includes essential amino acids, omega-3 fatty acids, and antioxidant properties. GRAPHICAL ABSTRACT

Numerical Simulation of Gas Atomization and Powder Flowability for Metallic Additive Manufacturing

The quality of metal powder is essential in additive manufacturing (AM). The defects and mechanical properties of alloy parts manufactured through AM are significantly influenced by the particle size, sphericity, and flowability of the metal powder. Gas atomization (GA) technology is a widely used method for producing metal powders due to its high efficiency and cost-effectiveness. In this work, a multi-phase numerical model is developed to compute the alloy liquid breaking in the GA process by capturing the gas–liquid interface using the Coupled Level Set and Volume-of-Fluid (CLSVOF) method and the realizable k-ε turbulence model. A GA experiment is carried out, and a statistical comparison between the particle-size distributions obtained from the simulation and GA experiment shows that the relative errors of the cumulative frequency for the particle sizes sampled in two regions of the GA chamber are 5.28% and 5.39%, respectively. The mechanism of powder formation is discussed based on the numerical results. In addition, a discrete element model (DEM) is developed to compute the powder flowability by simulating a Hall flow experiment using the particle-size distribution obtained from the GA experiment. The relative error of the time that finishes the Hall flow in the simulation and experiment is obtained to be 1.9%.

Effects of carbon on the synthesis and densification of tantalum carbide powder

Tantalum carbide (TaC) powder was synthesised at 1500 ºC by sol-gel and carbothermal reduction processes using tantalum pentachloride (TaCl5) and phenolic resin as the starting materials. The effects of the C/Ta ratios in the Ta-containing precursor on the reaction yield, microstructure, chemical composition, and sinterability of the powders were investigated. The results showed that a high C/Ta ratio was favourable for the formation of TaC powder. With an increase in the C/Ta ratio, the oxygen content of the powder decreased, whereas the free carbon content increased. Consolidated TaC ceramics with high relative density (> 97%) were obtained at 1900 ºC for 5min under 80MPa after sintering the powder synthesised at C/Ta ratios of 4.00 and above. However, the hardness and fracture toughness of the TaC ceramics were slightly reduced when the C/Ta ratio exceeded 4.00, owing to weak interface bonding caused by excessive free carbon in the powder. It was found that sintering TaC powders prepared at a C/Ta ratio of 4.00 produced dense TaC ceramics, with a Vickers hardness and fracture toughness of 16.54GPa and 3.72GPa∙m1/2, respectively.

Preparation of (Zr0.25Hf0.25Ta0.25Nb0.25)C high-entropy ceramic nanopowders via liquid-phase precursor route at a low temperature of 1500 °C

Using citric acid, ethylene glycol, ZrOCl2·8H2O, HfOCl2·8H2O, NbCl5, and TaCl5 as raw materials, based on the principle of Pechini coordination polymerization, the (Zr0.25Hf0.25Ta0.25Nb0.25)C high-entropy ceramic precursor solution was successfully prepared, and the corresponding high-entropy ceramic powder was formed by pyrolysis at a low temperature of 1500 °C. The molecular structure of the precursor and its pyrolysis products were analyzed and characterized by different analytical and testing methods. The results show that in the precursor solution, the organic compound and the metal ions form a stable three-dimensional macromolecular structure, so that the metal ions show a uniform distribution at the molecular level, shortening the diffusion path during the carbothermal reduction reaction, thereby enabling the formation of the single-phase high-entropy carbide ceramic powders at a relatively low temperature. The obtained ceramic powders have high purity, uniform element distribution, with an average particle diameter of approximately 42 nm and an oxygen content of about 1.61 wt%. The precursor solution prepared in this study has a moderate viscosity of 20–50 mPa s and a high ceramic yield of 45 %, which is ideal for the preparation of high-entropy ceramic matrix composites.

Anionic vacancy filled-up mechanism in (Ti0.2V0.2Nb0.2Ta0.2W0.2)Cx high-entropy carbide

Carbothermic reduction for high-entropy carbide preparation has it’s promising potential for industrialization application and the relevant basic theory for formation process required to clarify urgently. This research reports the anionic vacancy filled-up (AVF) mechanism during the formation of (Ti0.2V0.2Nb0.2Ta0.2W0.2)Cx high-entropy carbide powder by predictions of first-principles calculations, thermodynamic phase diagram calculations and verification by experimental preparation and characterization. The mechanism demonstrated that the rock-salt carbide matrix with superfluous anionic vacancy was formed firstly and the residual carbon substance continuously occupied the vacancies to an equilibrium state. The origin of the equilibrium anionic vacancy concentration was revealed from the perspective of the energy variation.

Research Progress on Laser Powder Bed Fusion Additive Manufacturing of Zinc Alloys.

Zinc, along with magnesium and iron, is considered one of the most promising biodegradable metals. Compared with magnesium and iron, pure Zn exhibits poor mechanical properties, despite its mild biological corrosion behavior and beneficial biocompatibility. Laser powder bed fusion (LPBF), unlike traditional manufacturing techniques, has the capability to rapidly manufacture near-net-shape components. At present, although the combination of LPBF and Zn has made great progress, it is still in its infancy. Element loss and porosity are common processing problems for LPBF Zn, mainly due to evaporation during melting under a high-energy beam. The formation quality and properties of the final material are closely related to the alloy composition, design and processing. This work reviews the state of research and future perspective on LPBF zinc from comprehensive assessments such as powder characteristics, alloy composition, processing, formation quality, microstructure, and properties. The effects of powder characteristics, process parameters and evaporation on formation quality are introduced. The mechanical, corrosion, and biocompatibility properties of LPBF Zn and their test methodologies are introduced. The effects of microstructure on mechanical properties and corrosion properties are analyzed in detail. The practical medical application of Zn is introduced. Finally, current research status is summarized together with suggested directions for advancing knowledge about LPBF Zn.

Solution-Free Melt-Grown CsGeI3 Polycrystals for Lead-Free Perovskite Photovoltaics: Synthesis, Characterization, and Theoretical Insights

Inorganic lead-free metal halide perovskites are being rigorously explored as a substitute for organic lead-based materials for various energy device applications. Germanium as a replacement for lead has been proven to give exemplary results theoretically, and there have been promising results. The current work presents the investigation of CsGeI3 (CGI) polycrystals grown using a solution-free melt-growth technique with low-cost precursors. A soak-ramp profile was designed to synthesize polycrystalline powders, which were evaluated for stability. X-ray diffraction and Raman spectroscopy analysis suggest the formation of CsGeI3 perovskite powders, matching the reported literature. Diffuse reflectance spectroscopy measurements showed the bandgap of the polycrystals to be around 1.6 eV. A prominent photoluminescence peak was obtained at 767 nm. The powders were examined using thermogravimetric analysis to assess the thermal degradation pathways. The as-grown inorganic perovskite polycrystals were relatively stable during storage under ambient conditions. Theoretical studies were also carried out to support the experimental data. Calculations were performed with different approximations, including local density approximation (LDA), generalized gradient approximation (GGA), and Heyd–Scuseria–Ernzerhof (HSE) approximation, out of which the HSE approximation yielded the most accurate results that matched the experimental findings. Moreover, for the CGI device with Ag electrodes simulated using SCAPS-1D software, highest incident photon-to-electron conversion efficiency was observed. The obtained optical and structural properties indicate the suitability of the synthesized CsGeI3 perovskite polycrystals for photovoltaic applications, specifically solar cells and light-emitting diodes.

Evaluation of Black Powder Formation in Natural Gas Transporting Pipelines Network and Study of Thermal Decomposition Kinetics under Inert Atmosphere

The corrosion product so-called black powder forms inside gas pipelines and negatively affects gas pipelines during the flow of gas therefore it needs continuous follow-up, collecting, and regular maintenance, to understand its physical characteristics and its nature is necessary for field operators to select the appropriate separation technique and to understand the possible roots causing the formation, there are certainly nanoparticles in the form of a large portion due to the effect of heat and moisture. The purpose of present work is to spot the light on black powder produced in gas pipelines by identifying the organic deposit around it, determining the percentage of deposit, determining the kinetic parameter, and thermodynamic parameters by utilizing TGA. Identification of metal power has been achieved by RDX. The black powder was subjected to three identifications first FTIR was to get clear information about the nature of the powder. It showed that the major was organic sulfurs and aromatic hydrocarbons deposited on the outer surface, XRD identified the kinds of iron oxides of iron oxide Fe2O3, and hydrated iron oxide FeOOH that formed mainly due to water condensate at dew point and water of periodical upsets, third TGA and DTG to determine the kinetics, and thermodynamics parameters and the percentages of organic hydrocarbons deposited on the outer surface of black powder by using Coats-Redfern at different heating rates including (10, 15, 20, and 25) Cº/min by using the flow rate 20 ml/min of helium as an inert gas, Activation energy increased 28.226-26.214 kJ/mole within the heating rate of 10-20 Co/min, and entropy showed a decrease -281.749 to -279.66 J/Kmol, and enthalpy showed the same trend.

Selective Isotropic Dry Etching of SiO2 Using F/H-Based Pulsed Remote Plasma and a Vapor Phase Solvent

Isotropic etching generally employs liquid-based wet etching techniques. However, due to the high integration of devices, conformal etching is challenging in patterns with a high aspect ratio because liquid chemicals struggle to penetrate inside the pattern. Additionally, during the drying process after chemical treatment, pattern collapse is observed due to surface tension. Therefore, there is a need for dry isotropic etching techniques to replace wet etching techniques in next-generation device manufacturing processes.Typically, when high selectivity SiO2 isotropic dry etching is required, F-base/H-based gas mixtures are utilized to form HF, which serves as an etchant for SiO2. SiO2 can be dry etched through two different mechanisms. First, HF reacts directly with H2O or alcohol, etching SiO2. The other way is to produce (NH4)2SiF6 salt from the reaction of NH3, which can be formed in a plasma containing NH3 and NF3. This (NH4)2SiF6 salt is sublimated and removed by a following heating process at a temperature over 100ºC.The process above has some disadvantages, such as lowering the etch selectivity of SiO2 over Si and Si3N4 because Si and Si3N4 can be etched by F radicals remaining in the plasma. This study aimed to overcome these disadvantages by controlling the F radical through pulsing the remote plasma during the discharging of F-based/H-based gas mixtures for the formation of HF. By pulsing the remote plasma, SiO2 could be selectively etched at a higher etch rate relative to those of Si and Si3N4. Additionally, various types of H/F-based gas mixtures that do not contain nitrogen while producing HF were investigated to prevent the formation of ammonium powders, which can be a source of contamination in the chamber. Futhermore, the etching mechanisms were identified through gas phase anlysis and surface analysis. Also, any possible surface damage during the etching process was investigated.

One-step spray solution combustion synthesis of nanostructured spherical Ca3Co4O9: The fuel effect

In the research, a one-step method for the rapid preparation of spherical nanostructured particles of Ca3Co4O9, involving the combustion of reactive aerosol drops containing calcium and cobalt nitrates as the metal precursors and hexamethylenetetramine as the fuel, is reported. The results of thermodynamic analysis and study of crystalline structure of obtained materials suggest that the reaction in the investigated system proceeds with heat release, which indicates its self-sustaining nature. Applying hexamethylenetetramine fuel at φ range of 0.4 – 0.6 and ambient temperature of 900 ℃ resulted in formation of Ca3Co4O9 powders with narrow particle size distribution of 0.2 – 1 µm. Microstructural studies revealed that the Ca3Co4O9 particles are hollow with nanometer-scale wall thicknesses and their surface consists of lamellar grains with sizes ranging from 14 to 100 nm.

Preparation of β-Cyclodextrin(CD)/Flavour CD Powder and Its Application on Flavour Improvement of Regular Coffee.

To improve the overall sensory evaluation of regular coffee, a mixture of β-CD/flavour CD powder was prepared by a freeze-drying method. Cyclodextrin inclusion complexes consist of eight compounds that are naturally present in coffee, specifically: 2,5-dimethylpyrazine, benzaldehyde, citral, linalool, limonene, phenethyl acetate, furfural, and ethyl acetate. These eight compounds naturally occur in coffee, making them safer than using other compounds. Moreover, these eight compounds are the primary active ingredients in coffee, significantly influencing its flavour profile. Therefore, choosing to complex these eight compounds with cyclodextrins can effectively enhance the taste of the coffee. XRD, FT-IR, and SDE-GC-FID were presented to study the formation of inclusion CD powder, the storage stability, chemical composition changes, and safety. Results show that by the cyclodextrin method of freeze-drying, the CD powder showed a stable encapsulated structure and increased stability of flavour compounds. Based on the coffee aroma analysis results, prepared CD powder can enhance the coffee's aroma score by 3.0-4.0 points and increase the flavour score by 2.1-3.5 points, and it can achieve preservation for a minimum of 181 days at 25 °C. Furthermore, under the requirements of the China national standard for additives, the mixture of β-CD/flavour CD powder was used for the cup testing with four regular coffees to obtain improved coffees. With the full score is 10, improved coffees could score extra 3.0-4.0 points on aroma and 2.1-3.5 on flavour compared to regular coffee. In addition, the CD powder also improves the quality of the coffee in terms of aftertaste, body, and sweetness. Overall, β-CD/flavour CD powders provide several advantages over the currently popular coffee bean processing methods, including improved reproducibility, enhanced controllability, and increased flexibility, while prioritizing safety. And it should be explored further with appropriate compounds given its potential for coffee aroma modulation.

Investigating the dielectric characteristics, electrical conduction mechanisms, morphology, and structural features of mullite via sol-gel synthesis at low temperatures

This research explores the fabrication of mullite precursor powder utilizing the sol-gel process at low temperatures. Silicon tetraethoxide (Si(C2H5O)4) and aluminum nitrate nonahydrate (Al(NO3)3.9H2O) were employed as the sources of SiO2 and Al2O3 oxides, respectively. Various analytical techniques, such as Fourier transform infrared spectroscopy (FTIR), thermogravimetry (TG), dilatometry, differential thermal analysis (DTA), and X-ray powder diffractometer (XRD), were utilized to investigate the formation and crystallization of the amorphous powder. The microstructure of specimens sintered at 1600 °C for 1 h was examined utilizing scanning electron microscopy (SEM). Measurements of hardness (HV) and coefficient of thermal expansion (CTE) were conducted on mullite samples heated to 1600 °C and then cooled, revealing an increase in HV from 888 to 1000 HV as the sintering temperature rose from 1500 to 1600 °C. The CTE of mullite within the temperature range of 50–1300 °C was determined as 5.23 × 10−6/°C. Additionally, the dielectric and electrical characterization of mullite was analyzed utilizing complex impedance spectroscopy at a frequency of 0.1–106 Hz and conductivity measurements over a temperature range of 40–400 °C. The real and imaginary parts of the dielectric permittivity exhibited frequency-dependent and temperature-dependent behaviors. Significantly, the observed variations in the imaginary component of the modulus and impedance maximum frequency point to a relaxation process that is not Debye-type, with calculated activation energies (Ea) consistent across different methods.

Promotion of Different Active Phases in MnOX-CeO2 Catalysts for Simultaneous NO Reduction and o-DCB Oxidation

AbstractMnOX-CeO2 catalysts with different Mn and Ce content were prepared to evaluate the effect of metal content on catalytic properties and activity in the simultaneous NO reduction and o-DCB oxidation, in order to elucidate the most active species for the process. Catalytic properties were evaluated by ICP-AES, XRD, skeletal FTIR, STEM-HAADF, XPS, N2-physisorption, H2-TPR, NH3-TPD and pyridine-FTIR. Catalysts with 85%Mn and 15%Ce molar content have been found to be the most active. Their excellent catalytic performance is related to the coexistence of Mn in different phases, i.e., Mn species strongly interacting with Ce and segregated Mn species. The effect of the preparation methods has also been deeply investigated: Co-precipitation method (CP) leads to Mn segregation as Mn2O3, whereas sol-gel preparation method (SG) promotes the formation of an amorphous powder. The synergy between segregated Mn2O3 species and Mn species in high interaction with Ce (resulting in a mixed oxide phase) leads to the presence of Mn with different oxidation states. This effect, together with the high oxygen mobility caused by structural defects, enhances redox, acidic and oxidative properties. The improvement of catalytic properties with Mn content also favors NO reduction side-reactions, with N2O and NO2 being the most important by-products, whereas it limits the production of chlorinated organic by-products in o-DCB oxidation.

Optimization of the gas system for gas–water combined atomization technique in FeSiBC amorphous powder production

The gas–water combined atomization is an advanced technology for Fe-based amorphous powder preparation, and its gas/water system parameters have significant impacts on powder properties. In this study, numerical simulations and industrial trials were combined to optimize the gas atomization parameters. The results showed that increasing the atomization pressure promotes the transition of the flow field to the closed wake. Moreover, the median particle size was significantly refined and the cooling rate was improved. Extending the extrusion length facilitated the decrease in suction pressure, while excessively long extrusion lengths led to instability in the atomization process. The decrease in delivery tube diameter enhances droplet breakup and cooling, but increases the risk of clogging. Industrial trials at different atomization pressures showed that low atomization pressure led to the formation of needle-shaped powder, and the FeSiBC amorphous powder prepared at 3.0 MPa exhibited optimal comprehensive properties, with saturation magnetization of 166.1 emu·g−1 and coercivity of 4.5 Oe.

The effect of different temperature rate on sol-gel approach derived M-type hexagonal BaFe12O19 using D-mannose as a fuel: Synthesis, structural, thermal gravimetric and magnetic properties

In this article, we reported that the BaFe12O19 powders were prepared using the effective sol-gel process under different calcination temperatures, i.e., 700–900 °C for 2 h. The structural effects of the temperature rate on the phase formation, morphological and magnetic properties of the as-prepared powders have been analyzed and discussed. The X-ray diffraction pattern confirmed the hexaferrite phase formation at calcined temperature range of 800 °C with no secondary phase and the particles size are about 45 nm–65 nm. The Fourier-transform infrared (FT-IR) spectra show that the intensity frequencies for hexaferrite site stretching were observed at 601 and 443 cm−1 from Fe–O and Ba–O bonds, respectively. The micro-sized flakes morphological structure with particle sizes ranging from 45 to 65 nm by strongly agglomerated powders of the hexaferrite phase is examined through the field emission scanning electron microscopy (FESEM) technique for the good-quality calcined 800 °C. Additionally, the effect of the calcination rates at 800 °C on the material features was analyzed by the energy-dispersive X-ray, X-ray photoelectron spectroscopy (XPS), etc. The magnetic properties, such as saturation magnetization and coercive field of the as-prepared nanomaterials were analyzed using the vibrating sample magnetometry (VSM) technique. The hysteresis loop of the BaFe12O19 nanomaterials calcined at 800 °C for 2 h showed excellent magnetic properties, with a higher saturation magnetization curve of 55.774 emu/g and a coercivity (Hc) of 5079 kOe. The dark brown colored annealed 800 °C nanomaterials can be useful as a ceramic color pigment, which has several industrial applications.

2. Formation and Production of Powder and Particles 2.3 Crystallization 2.3.6 Application of Local Supersaturation Fields Generated around Fine Gas-Liquid Interfaces for Crystallization Operations

2. Formation and Production of Powder and Particles 2.3 Crystallization 2.3.6 Application of Local Supersaturation Fields Generated around Fine Gas-Liquid Interfaces for Crystallization Operations

Integrating Simulation and Experimentation for Optimized Compaction Powder Forming: A Study on RVE Size, Friction, and Particle Size Distribution

This work comprehensively represents multi-particle finite element simulations for powder compaction, including examining representative volume element (RVE) size, friction effects, and particle distribution. The analysis provides valuable insights into the correlation between RVE size and relative density, facilitating a comprehensive understanding of the sensitivity of process parameters to relative density. Furthermore, the research investigates the impact of particle size distribution. Moreover, the study investigates the influence of friction between powder particles and the die wall. Results demonstrate that increased friction leads to a significant reduction in relative density.

A New Sight on the Influence of Molten Salt in the Preparation of (Ta, Nb, Ti) C Nanopowder

The molten salt method (MSM) is an effective approach for obtaining multicomponent carbide nanopowders at low temperatures. However, the presence of impurities limits its application in the lower‐temperature domains. To address this issue, (Ta, Nb, Ti) C nanopowders are fabricated by the MSM at 1100–1400 °C, and the dual‐route synthesis mechanism is revealed. Results indicate that the synthesis temperature of pure (Ta, Nb, Ti) C nanopowders can be decreased with the addition of molten salt, which is determined by the formation and decomposition of the intermediates. During the synthesis process, the molten salt can provide the liquid‐phase environment for the combination reaction between metal powders and carbon, facilitating the formation of homogeneous and nanosized powders. Meanwhile, the molten salt reacts with impurities to generate intermediates including KTaO3 and K1.04Ti8O16 at low temperatures, which subsequently form carbides through thermal reduction. This transformation can decrease the energy barrier of the synthesis process.

Mechanics and deformation behavior of lithium-ion battery electrode during calendering process

The calendering process in lithium-ion battery electrode manufacturing is pivotal and significantly affects battery performance and longevity. However, current research on the mechanical and deformation characteristics of lithium-ion battery electrodes during calendering is limited, and a systematic theoretical foundation for informing practical production is lacking. This study investigated the mechanics and deformation behavior of lithium-ion battery electrodes during calendering through experimental methods. Data on the calendering pressure for electrodes at varying compression rates were gathered, revealing a correlation between the calendering pressure and compression rate that aligns well with the Kawakita equation commonly used in powder forming. Furthermore, the study examined the effects of the roller diameter and roller surface temperature on the calendering pressure. Within the typical compression rate range, a linear relationship was observed between the compression rate and the percentage elongation of the battery electrode. The study also explored how the roller diameter, roller surface temperature, and number of calendering passes influence the percentage of elongation. A quantitative formula linking the roller diameter to the percentage elongation of the battery electrode was proposed considering the effect of the roller diameter. Additionally, through electrode cleaning experiments, the study identified the coordination relationship between the extension of the electrode coating and the current collector. Mercury intrusion porosimetry (MIP) tests were conducted to elucidate the influence of calendering on the porosity, pore size distribution and specific surface area of the electrode coating. This research offers valuable insights and a theoretical basis for optimizing the calendering process in lithium-ion battery electrode production.