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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Rising ecosystem water demand exacerbates the lengthening of tropical dry seasons

Precipitation-based assessments show a lengthening of tropical dry seasons under climate change, without considering simultaneous changes in ecosystem water demand. Here, we compare changes in tropical dry season length and timing when dry season is defined as the period when precipitation is less than: its climatological average, potential evapotranspiration, or actual evapotranspiration. While all definitions show more widespread tropical drying than wetting for 1983-2016, we find the largest fraction (48.7%) of tropical land probably experiencing longer dry seasons when dry season is defined as the period when precipitation cannot meet the need of actual evapotranspiration. Southern Amazonia (due to delayed end) and central Africa (due to earlier onset and delayed end) are hotspots of dry season lengthening, with greater certainty when accounting for water demand changes. Therefore, it is necessary to account for changing water demand when characterizing changes in tropical dry periods and ecosystem water deficits.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Efficiency Limits of Evaporative Fabric Drying Methods

Cloth drying is a major consumer of energy, and most drying is conducted by evaporative methods. The evaporative drying energy efficiency limit is commonly assumed to be 100%: one unit of latent heat removed per unit of energy expended. However, this ignores the “free drying” available from unsaturated ambient air and the possible role of heat pumping. We demonstrate that efficiency limits for evaporative drying are fundamentally related to both drying rate and ambient psychrometric conditions. A relationship among efficiency, drying rate, and ambient conditions is quantified for several evaporative drying technologies, and a comparison among evaporative technologies is provided. In addition, a comparison is provided between efficiency limits and state of the art device performance. This research will help guide future research in the most promising directions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Entrainment, Detrainment, and Dilution of Dry and Moist Atmospheric Thermals

Here this study examines the entrainment, detrainment, and dilution of dry and moist (cloud) atmospheric thermals in large-eddy simulations. In a neutrally stable environment (with respect to dry dynamics), moist thermals have an increase in radius R with thermal height z t (α ≡ dR/dz t ) about 4 times smaller compared to dry thermals when density stratification is considered and ~2.4 times smaller without density stratification (i.e., applying the Boussinesq approximation). An analytic expression relating α to several dimensionless parameters is derived from the thermal impulse–circulation relation to clarify the factors impacting α. This expression shows that the difference in buoyancy structure between moist and dry thermals, with buoyancy concentrated in the central cores of moist thermals owing to latent heating, explains their smaller spreading rates. Individual contributions of entrainment and detrainment are analyzed using a direct parcel-based approach in the simulations. Moist thermals have similar fractional detrainment but much smaller fractional entrainment rates compared to dry thermals, consistent with the differences in α. Despite having smaller α, moist thermals are similarly dilute (quantified by a passive tracer) as dry thermals because of their greater mixing efficiency with the environment. Thus, moist thermals are substantially dilute but expand much less in size/volume as they rise compared to dry thermals. The α values for moist thermals in (dry) neutral and statically stable environments are similar, but fractional entrainment and especially detrainment rates are greater in the stable environment. Large detrainment rates are associated with a breakdown of the broader thermal vortex ring structure, especially with low environmental relative humidity, attributed in part to evaporation and buoyancy reversal.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Tropical Tree Species Identity and Diameter at Breast Height in a Throughfall-Reduction Drying Experiment in Four Lowland Panamanian Forests

Objectives: Climatic drying is predicted for many tropical forests, yet effects on soil properties across moisture and soil gradients within tropical forests remain poorly characterized, hampering predictions of forest-climate feedbacks. We hypothesized that drying would suppress soil CO2 fluxes (i.e., respiration) in already-drier tropical forests by further reductions in soil moisture, but increases CO2 fluxes in wetter tropical forests by alleviating anaerobiosis and soil saturation. We measured soil CO2 fluxes, soil moisture, soil temperature, and forest floor biomass during wet-dry cycles (2015 – 2022) in four Panamanian forests that vary in rainfall and soil fertility. We also surveyed all tree species and identified to species in 2018 and 2019.Results: We found that soil moisture peaked in the wet season and declined in the dry season. Measured soil CO2 fluxes declined in the dry season and peaked in the early wet season ahead of peak soil moisture, resulting in a lower soil moisture optimum for respiration than previously modeled. Chronic throughfall exclusion also suppressed soil moisture across the four forests to 20cm depths, and also initially suppressed soil CO2 fluxes across forests. There was sustained suppression of soil CO2 fluxes after four years in the wettest forest only (-28 ± 4% during the dry season), but elevated soil CO2 fluxes in a fertile forest after four years (+75 ± 28% during the late wet season). The unexpected negative drying effect in the wettest, most infertile forest could have resulted from reduced vertical flushing of nutrients into soils, as the drying effect increased with time. Including hydro-nutrient interactions in ecosystem models could improve predictions of tropical forest-climate feedbacks (results presented in Cusack et al. 2023). Datasets included: Datasets included here include .csv and .xls files for tree species identity and diameter at breast height (dbh) in the study plots. There is also a .kml file that includes coordinates for all 32 plots included in the study of four forests (n = 4 throughfall reduction and n = 4 control plots per site). No special software is needed to open these files.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Observational constraints on wet and dry deposition of black carbon to land surfaces (Final Report)

This project focused on providing observational constraints on dry deposition of black carbon and aerosol particles, and the extent to which wet and dry deposition impacts the lifetime of aerosols in the atmosphere. The proposed work tackled the following questions: To what extent dry versus wet deposition controls the removal of BC from the atmosphere, and thus atmospheric BC concentrations? Is BC dry deposition controlled by the same processes as non-refractory aerosol dry deposition? We successfully made eddy covariance flux measurements at the DOE Southern Great Plains site of size-resolved aerosol number fluxes with an ultra high sensitivity aerosol spectrometer (UHSAS) and of black carbon mass and number fluxes using a single particle soot photometer (SP2). We also collected precipitation samples for off-line measurement of rBC using a wet deposition collector. Using these measurements, we identified that wet deposition was the dominant control for black carbon lifetime, but that dry deposition was poorly constrained in models. We developed a new parameterization for particle dry deposition, and applied it to global models to demonstrate the importance of dry deposition in air pollution and radiative effect estimates.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Response of a Pressurized Water Reactor Dashpot Region to Commercial Drying Cycles

The purpose of this report is to document updates to the simulation of commercial vacuum drying procedures at the Nuclear Energy Work Complex at Sandia National Laboratories. Validation of the extent of water removal in a dry spent nuclear fuel storage system based on drying procedures used at nuclear power plants is needed to close existing technical gaps. Operational conditions leading to incomplete drying may have potential impacts on the fuel, cladding, and other components in the system. A general lack of data suitable for model validation of commercial nuclear canister drying processes necessitates additional, well-designed investigations of drying process efficacy and water retention. Scaled tests that incorporate relevant physics and well-controlled boundary conditions are essential to provide insight and guidance to the simulation of prototypic systems undergoing drying processes. This report documents testing updates for the Dashpot Drying Apparatus (DDA), an apparatus constructed at a reduced scale with multiple Pressurized Water Reactor (PWR) fuel rod surrogates and a single guide tube dashpot. This apparatus is fashioned from a truncated 5×5 section of a prototypic 17×17 PWR fuel skeleton and includes the lowest segment of a single guide tube, often referred to as the dashpot region. The guide tube in this assembly is open and allows for insertion of a poison rod (neutron absorber) surrogate.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

In-line measurements of below-the-surface food deformation during drying with an interference-based optical fiber strain sensor

Real-time measurements of food deformation are important for quality control in drying, yet they pose significant challenges. In this study, we developed an interference-based optical fiber strain sensor to enable in-line, continuous, below-the-surface strain measurements in drying of soft food samples. Compared to a strain resolution of 8 × 10 -4 at zero strain and 7.2 × 10 -3 at 0.20 strain reported in our previously published work, the present study achieves markedly improved resolutions of 1.3 × 10 -4 at zero strain and 7.8 × 10 -4 at 0.25 strain, which strains are the lower and higher boundaries of the dynamic range, respectively. This nearly order-of-magnitude improvement is attributed to the unique interference-based sensing mechanism, no need for calibration to convert optical signals to strain, and the system-design-enabled immunity to fiber-disk misalignments and light source intensity fluctuations. To demonstrate the in-line process monitoring, deformation measurements of fresh banana slices and sugar cookie doughs were carried out in a benchtop oven and an industrial-scale hot-air pilot dryer, respectively. In both dryers, strain measurements were continuously measured during the whole drying process at various depths and radii below the sample surfaces, with the strains up to 25%. Computer vision was used only in the benchtop drying to confirm the faithfulness of the fiber sensor measurements and cannot provide below-the-surface measurements. The measured spatiotemporal deformation allowed us to confirm the shell-hardening effect and to determine the speed and location of large deformation changes in the whole drying process, the latter of which is related to the sample cracking. To the best of the authors’ knowledge, this study is the first to report on an interferometry-based fiber sensor to measure food deformation. This sensor and the sensing mechanism have high potential for real-time process monitoring and control to prevent over-drying or cracking during drying processes.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

High-throughput and high-performance lithium-ion batteries via dry processing

A scalable powder-to-electrode dry processing strategy mainly based on powder dry mixing and rolling/calendering is rationally designed. The dry processed electrodes show lower tortuosity compared to that of conventional slurry-based electrodes. The dry-processed high-loading graphite anodes (6.6 mAh cm -2 ) and LiNi 0.6 Mn 0.2 Co 0.2 O 2 cathodes (6.0 mAh cm -2 ) exhibit promising electrochemical performance in half-cells and full-cells. The full-cells with both electrodes from dry processing demonstrates superb rate performance to their counterpart with conventional slurry-based electrodes and delivers of capacity retentions of 74.1 % and 63.6 % over 400 and 800 cycles, respectively. Notably, the initial Coulombic efficiency of the dry processed graphite anodes is low ascribed to polytetrafluoroethylene binder. Finally, the results suggest that dry processing is promising for future lithium-ion battery manufacturing and also pinpoint the needs of modification for the polytetrafluoroethylene binder in the graphite anodes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Revisiting particle dry deposition and its role in radiative effect estimates

Wet and dry deposition remove aerosols from the atmosphere, and these processes control aerosol lifetime and thus impact climate and air quality. Dry deposition is a significant source of aerosol uncertainty in global chemical transport and climate models. Dry deposition parameterizations in most global models were developed when few particle deposition measurements were available. However, new measurement techniques have enabled more size-resolved particle flux observations. We combined literature measurements with data that we collected over a grassland in Oklahoma and a pine forest in Colorado to develop a dry deposition parameterization. We find that relative to observations, previous parameterizations overestimated deposition of the accumulation and Aitken mode particles, and underestimated in the coarse mode. These systematic differences in observed and modeled accumulation mode particle deposition velocities are as large as an order of magnitude over terrestrial ecosystems. As accumulation mode particles form most of the cloud condensation nuclei (CCN) that influence the indirect radiative effect, this model-measurement discrepancy in dry deposition alters modeled CCN and radiative forcing. We present a revised observationally driven parameterization for regional and global aerosol models. Using this revised dry deposition scheme in the Goddard Earth Observing System (GEOS)-Chem chemical transport model, we find that global surface accumulation-mode number concentrations increase by 62% and enhance the global combined anthropogenic and natural aerosol indirect effect by −0.63 W m −2 . Our observationally constrained approach should reduce the uncertainty of particle dry deposition in global chemical transport models.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Engineering Scale Drying of Aluminum-Clad Spent Nuclear Fuel: Experiment Report

Engineering-scale tests were performed to evaluate the relative effectiveness of forced gas and vacuum-drying processes on aluminum-clad spent nuclear fuel (ASNF) in preparation for extended dry storage. Drying models were developed to improve confidence in the likely range of conditions at the start of dry storage and to understand the factors most significant to each process. Testing was performed at the Holtec International Forced Helium Dehydration training facility in Camden, New Jersey, by students from the University of South Carolina in collaboration with Idaho National Laboratory. A full-size Type 1a basket, with a full-diameter vessel configuration (based on the Department of Energy standardized canister design), was used in combination with a 10 assembly surrogate ASNF arrangement to provide a proxy for geometry. A resistance heater incorporated in one assembly simulated the influence of 100 W decay heat. This instrumented chamber allowed testing of the removal of bulk water, physisorbed water, and chemisorbed water over a range of operating parameters with either drying process. Thick oxide films were grown on aluminum test plates to mimic the ASNF surface chemistry. These one-use test plates were housed within select assemblies during drying. Post-test analysis of these plates gave a measure of the moisture removed during each test, which was compared to a control. Instrumentation provided detailed thermal, humidity, and gas or pressure data relevant to each test. Model simulations generally compared favorably to instrument data for the tests. While both processes were able to remove bulk water, removal of chemisorbed water was shown to depend heavily on local temperature. To the disadvantage of vacuum drying, operations approaching or exceeding 220°C achieved consistently more dehydroxylation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Experimental and computational design tools for industrial drying processes: Challenges in process‐limit prediction

Abstract The coating and drying of inks and slurries are important steps to manufacture a plethora of products. Drying processes, particularly, comprise energy‐intensive steps that affect product cost and quality. Prior work has highlighted failures of various multicomponent diffusivity models to conserve mass in dryer modeling and challenges in predicting process limits given variability in published values of key thermodynamic parameters. Herein, we develop a computational model and benchtop drying experiments to investigate these concerns for drying polymer‐laden coatings. Model predictions of process limits in a single‐zone drying oven demonstrate that published variability in Flory–Huggins parameter yields large variations in predicted operating temperatures above which blistering occurs. This indicates that caution should be exercised when choosing approaches to obtain or predict the Flory–Huggins parameter, and that both benchtop drying experiments and a set of additional experiments, such as sorption experiments, are needed to fully characterize and optimize a given drying process.

Parrish, Chance↗
DOE OSTI2022

Effects of experimental and seasonal drying on soil microbial biomass and nutrient cycling in four lowland tropical forests

Changes in precipitation represent a major effect of climate change on tropical forests, which contain some of the earth’s largest terrestrial carbon (C) stocks. Such changes are expected to influence microbes, nutrients, and the fate of C in tropical forest soils. To explore this, we assessed soil microbial biomass, potential extracellular enzyme activities, and nutrient availability in a partial throughfall exclusion experiment in four seasonal lowland tropical humid forests in Panama with wide variation in precipitation and soil fertility. We hypothesized that throughfall exclusion would reduce microbial biomass and activity and accentuate dry season soil nutrient accumulation, with larger effects in wetter, less droughtresistant forests. We observed a baseline seasonal pattern of decreased microbial biomass and increased extractable dissolved organic C (DOC), total dissolved nitrogen (TDN), nitrate (NO 3 – ), and resinextractable phosphorus (P) in the dry season, with the strongest patterns for nitrogen (N). However, potential enzyme activities showed no consistent seasonality. In line with seasonal drying, throughfall exclusion decreased soil microbial biomass in the wet season and increased TDN and NO 3 – , especially in the dry season. In contrast to seasonal drying, throughfall exclusion decreased DOC and did not affect resinextractable P, but slightly decreased potential phosphatase activities. Potential enzyme activities varied among sites and sampling times, but did not explain much variation in microbial biomass or substrate availability. We conclude that reduced rainfall in tropical forests might accentuate some dry season patterns, like reductions in microbial biomass and accumulation of extractable nutrients. However, our data also suggest new patterns, like reduced inputs of DOC to soils with drying, which could have cascading effects on soil ecological function and C storage.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Excipient screening by lyophilization provides insights into spray drying formulations for nanoparticle vaccines

Nanoparticles have shown great promise as delivery platforms in the development of tunable and safe vaccines. Nanolipoprotein particles (NLPs), also known as nanodiscs, are discoidal nanoparticles composed of a lipid bilayer stabilized at their periphery by apolipoproteins. Under the right conditions, the NLP self-assembly process is highly customizable in terms of lipids and apolipoprotein constituents, allowing for tunable physical and chemical characteristics. This flexibility allows a wide range of vaccine antigens and adjuvants to be incorporated onto the NLP platform for tailored vaccine design. The stability of NLPs during long term storage is a very important factor in developing a vaccine delivery platform suitable for widespread global use. When stored in a solution for extended periods of time, NLPs dissociate into their corresponding lipids and protein constituents, leading to particle degradation. Proper stabilization of NLPs can often be achieved by lyophilization (i.e. freeze-drying), a method widely used for various applications including pharmaceuticals. This process, however, can be damaging to particles without the presence of lyoprotectants or excipients that help maintain particle stability during lyophilization. Another method used to stabilize vaccines and pharmaceuticals is spray drying, a process that converts liquid formulations into dry powders through controlled heating and airflow. While spray drying is rapid, scalable, and cost-effective, lyophilization is typically a gentler process that better retains biomolecule structure and function. Both processes use excipients for particle stabilization, so lyophilization can be used as a surrogate to test stability of NLPs, to down-select formulations that may withstand the harsher conditions of spray drying. To screen different formulations, NLPs were synthesized and purified to homogeneity by size exclusion chromatography (SEC) and samples were prepared with a wide range of lyoprotectants and/or excipients. To assess the protective effects of excipients on NLPs upon spray drying, both pre- and post-lyophilized samples were analyzed by SEC. To assess the protective effects upon heating (encountered during the spray drying process), NLP samples were incubated at elevated temperatures prior to SEC analysis. The lyoprotectants and excipients evaluated in this study had different efficiencies in protecting NLPs during lyophilization and heating tests. Trehalose, for example, exhibits stabilization on NLPs both upon lyophilization and heating whereas leucine accelerated NLP dissociation. Although some lyoprotectants are effective by themselves, different combinations can decrease the stabilization of NLPs. Shelf-stable vaccines that do not require cold-chain storage are essential for global accessibility and our findings provide fundamental insight into how to advance NLP-based vaccines for these applications.

Serrano, Litzay J [Lawrence Livermore National Lab↗
DOE OSTI2024

Chemically Amplified, Dry-Develop Poly(aldehyde) Photoresist

The catalytic decomposition of poly(phthalaldehyde) with a photoacid generator can be used as dry-develop photoresist, where the exposed film depolymerizes into small molecules to allow the development of features via controlled vaporization. Higher temperatures enabled shorter dry-development times, but also promoted faster photoacid diffusion that compromised pattern fidelity. Trihexylamine was used as a base quencher to counteract acid diffusion in a phthalaldehyde-propanal co-polymer photoresist. The propanal co-monomer in the polymer improves the vaporization rate because it has a higher vapor pressure than phthalaldehyde. Addition of the base quencher was found to improve the contrast, pattern fidelity, and ease-of-handling of the dry-develop resist in a direct-write UV lithography tool. The dry-development of 4 μ m features was achieved with no appreciable residue. For large area features, a spatially variable exposure method was used to direct the residue away from the exposed area. The gradient exposure method was used to produce 100 μ m features. Plasma etching after dry-development was also used to achieve residue-free dry-developed patterns. These results show the benefits of incorporating base additives into a dry-develop depolymerizable resist system and highlight the need for addressing residue formation.

Materials Science↗
DOE OSTI2021

Update on the Simulation of Commercial Drying of Spent Nuclear Fuel

The purpose of this report is to document improvements in the simulation of commercial vacuum drying procedures at the Nuclear Energy Work Complex at Sandia National Laboratories. Validation of the extent of water removal in a dry spent nuclear fuel storage system based on drying procedures used at nuclear power plants is needed to close existing technical gaps. Operational conditions leading to incomplete drying may have potential impacts on the fuel, cladding, and other components in the system. A general lack of data suitable for model validation of commercial nuclear canister drying processes necessitates additional, well-designed investigations of drying process efficacy and water retention. Scaled tests that incorporate relevant physics and well-controlled boundary conditions are essential to provide insight and guidance to the simulation of prototypic systems undergoing drying processes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

A thermal-driven graupel generation process to explain dry-season convective vigor over the Amazon

Large-eddy simulations (LESs) are conducted for each day of the intensive observation periods (IOPs) of the Green Ocean Amazon (GoAmazon) field campaign to characterize the updrafts and microphysics within deep convective cores while contrasting those properties between Amazon wet and dry seasons. Mean Doppler velocity (V dop ) values simulated using LESs are compared with 2-year measurements from a radar wind profiler (RWP) as viewed by statistical composites separated according to wet- and dry-season conditions. In the observed RWP and simulated LES V dop composites, we find more intense low-level updraft velocity, vigorous graupel generation, and intense surface rain during the dry periods compared with the wet periods. To investigate coupled updraft–microphysical processes further, single-day golden cases are selected from the wet and dry periods to conduct detailed cumulus thermal tracking analysis. Tracking analysis reveals that simulated dry-season environments generate more droplet-loaded low-level thermals than wet-season environments. This tendency correlates with seasonal contrasts in buoyancy and vertical moisture advection profiles in large-scale forcing. Employing a normalized time series of mean thermal microphysics, the simulated cumulus thermals appear to be the primary generator of cloud droplets. When subsequent thermals penetrate the ice crystal layer, droplets within the thermals interact with entrained ice crystals, which enhances riming in the thermals. This appears to be a production pathway of graupel/hail particles within simulated deep convective cores. In addition, less-diluted dry-case thermals tend to be elevated higher, and graupel grows further during sedimentation after spilling out from thermals. Therefore, greater concentrations of low-level moist thermals likely result in more graupel/hail production and associated dry-season convective vigor.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Numerical coupling of aerosol emissions, dry removal, and turbulent mixing in the E3SM Atmosphere Model version 1 (EAMv1) – Part 1: Dust budget analyses and the impacts of a revised coupling scheme

Abstract. An earlier study evaluating dust life cycle in the Energy Exascale Earth System Model (E3SM) Atmosphere Model version 1 (EAMv1) has revealed that the simulated global mean dust lifetime is substantially shorter when higher vertical resolution is used, primarily due to significant strengthening of dust dry removal in source regions. This paper demonstrates that the sequential splitting of aerosol emissions, dry removal, and turbulent mixing in the model's time integration loop, especially the calculation of dry removal after surface emissions and before turbulent mixing, is the primary reason for the vertical resolution sensitivity reported in that earlier study. Based on this reasoning, we propose a revised numerical process coupling scheme that requires the least amount of code changes, in which the surface emissions are applied before turbulent mixing instead of before dry removal. The revised scheme allows newly emitted particles to be transported aloft by turbulence before being removed from the atmosphere, and hence better resembles the dust life cycle in the real world. Sensitivity experiments show that the revised process coupling substantially weakens dry removal and strengthens vertical mixing in dust source regions. It also strengthens the large-scale transport from source to non-source regions, strengthens dry removal outside the source regions, and strengthens wet removal and activation globally. In transient simulations of the years 2000–2009 conducted using 1∘ horizontal grid spacing, 72 vertical layers, and unchanged tuning parameters of emission strength, the revised process coupling leads to a 40 % increase in the global total dust burden and an increase of dust lifetime from 1.8 to 2.5 d in terms of 10-year averages. Weakened dry removal and increased mixing ratios are also seen for other aerosol species that have substantial surface emissions, although the changes in mixing ratio are considerably smaller for the submicron species than for dust and sea salt. Numerical experiments confirm that the revised coupling scheme significantly reduces the strong and non-physical sensitivities of model results to vertical resolution in the original EAMv1. This provides a motivation for adopting the revised scheme in EAM as well as for further improvements on the simple revision presented in this paper.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Micron Size NaCrO 2 Particles Enable High‐loading Dry‐processed Electrode for Sodium Ion Batteries

Dry-process fabrication using fibrillatable binder is emerging as a promising method to produce high-loading electrodes for energy storage applications, favored by its cost-efficiency and eco-friendliness. While previous studies have demonstrated the advantages of dry process over the traditional slurry method, there remains a gap in understanding how the particle size of active materials influences the mechanical and electrochemical performance of dry electrodes. In this study, four different particle size NaCrO 2 materials (Average size, S-NCO: 0.6 µm, M1-NCO 1.5 µm, M2-NCO: 4.4 µm, and L-NCO: 9.9 µm) are synthesized to investigate the effect of particle size on dry-processed high-loading electrodes. The findings reveal that the larger micron-sized (>4.4 µm) NCO dry films exhibit significantly improved tensile strength and electrochemical performance, primarily ascribed to the low film porosity, abundant inter-particle connection by the binder, comprehensive carbon coverage, and efficient percolation of the conductive pathway. Notably, a full cell incorporated with a high loading (5.2 mAh cm −2 ) and high active material ratio (96.5 wt.%) L-NCO film electrode demonstrates promising cycling stability and rate capability. Furthermore, these results provide valuable insights regarding the design and fabrication of dry-processed electrodes for future energy storage applications.

25 ENERGY STORAGE↗