Multiscale Modelling and Scale-up of Battery Slurry Mixing Using Coupled CFD-DEM

Battery electrode manufacturing relies on effective mixing of active materials, conductive additives, binders and solvents to produce homogeneous slurries with suitable properties for coating. However, scaling mixing processes from laboratory to industrial production remains challenging and often relies on trial-and-error, increasing development time, material waste and cost.<br /> <br /> This PhD project will develop a physics-based computational framework for battery slurry mixing and scale-up, combining Computational Fluid Dynamics (CFD) and Discrete Element Method (DEM) with experimental validation. The research will investigate the complex particle-fluid interactions occurring during mixing and establish relationships between material properties, mixer design, operating conditions and slurry quality.<br /> <br /> The main objectives are to:<br /> - Develop high-fidelity CFD-DEM models of battery slurry mixing.<br /> - Investigate the effects of material properties, mixer geometry and operating parameters on slurry homogeneity, mixing efficiency and energy consumption.<br /> - Experimentally validate the models using laboratory-scale mixing.<br /> - Develop reliable methodologies for translating mixing behaviour from laboratory to pilot/industrial scales.<br /> <br /> The project will ultimately deliver predictive modelling tools to support faster process development, reduce experimental trial-and-error, and enable more efficient scale-up of battery manufacturing.<br />

<p style="margin-bottom:11px"><strong>Methodology</strong><br /> The project will combine physics-based computational modelling with experimental validation. High-fidelity CFD-DEM models will be developed to capture fluid flow, particle dynamics and particle-fluid interactions during battery slurry mixing. A systematic parametric study will investigate the effects of material properties, mixer geometry and operating conditions on mixing performance. Laboratory experiments using a vacuum planetary mixer will provide rheological and mixing data for model validation. The validated framework will then be extended to pilot/industrial-scale mixing systems, supported by collaboration with UKBIC and CPI, to develop and assess reliable scale-up methodologies.</p> <p><br /> <strong>Background</strong><br /> Battery slurry mixing is a critical step in electrode manufacturing, directly influencing slurry homogeneity, rheology, coating quality and ultimately battery performance. However, the complex interactions between active materials, conductive additives, binders and solvents make the process difficult to understand and optimise. Current scale-up from laboratory to industrial mixers still relies heavily on empirical approaches and trial-and-error, leading to high material consumption, cost and development time. Physics-based modelling offers an opportunity to reveal the underlying mixing mechanisms and develop predictive scale-up strategies, supporting more efficient, consistent and sustainable battery manufacturing.</p> <p><br /> <strong>Skills Required</strong><br /> Applicants should have a first-class or strong 2:1 degree (or equivalent) in Mechanical, Chemical, Materials Engineering, Physics, or a closely related discipline. A relevant Master’s degree is desirable but not essential. Candidates should have a strong interest in computational modelling, fluid mechanics and battery manufacturing. Experience with CFD, DEM, multiphase flow modelling, numerical methods, or programming (e.g., Python, Matlab or C++) would be advantageous. Experimental experience in rheology, particle processing or battery materials is desirable. Applicants should demonstrate strong analytical, problem-solving and communication skills and be motivated to work across computational, experimental and industrial environments.</p> <p><br /> <strong>Industry/external partners</strong><br /> The project will involve collaboration with UK Battery Industrialisation Centre (UKBIC) and CPI, providing industrial insight into battery slurry mixing, process scale-up and manufacturing challenges. The partners will contribute through technical discussions, advisory meetings and guidance on industrially relevant operating conditions and scale-up requirements. Where appropriate, access to pilot-scale processing knowledge and data will support comparison between laboratory and industrial mixing systems. Their involvement will ensure that the developed modelling framework addresses real manufacturing challenges and strengthens the translation of research outcomes towards practical battery production.</p>

<p>To apply for this project you will need to <a href="https://www.leeds.ac.uk/research-applying/doc/applying-research-degrees">make a formal application for research degree study through the University's website</a>. You will need to create a login ID with a username and PIN. </p> <ul> <li>For <strong>‘Application type’</strong> please select <strong>‘Research Degrees – Research Postgraduate’. </strong></li> <li>The <strong>admission year</strong> for this project is<strong> 2027/28 Academic Year.</strong></li> <li>You will need to select your <strong>‘Planned Course of Study’</strong> from a drop-down menu. For this project, scroll down and select <strong>‘EPSRC DLA (Engineering, Biological Sciences, Medicine)’ </strong></li> <li>The project start date for this project is <strong>01/10/2027</strong>, please use this as your <strong>Proposed Start Date of Research</strong>. </li> <li>Please state clearly in the research information section that the research degree you wish to be considered for is <strong>‘Multiscale Modelling and Scale-up of Battery Slurry Mixing Using Coupled CFD-DEM’</strong> as well as <a href="https://eps.leeds.ac.uk/mechanical-engineering/staff/12256/dr-masoud-jabbari">Dr Masoud Jabbari </a>as your proposed supervisor.</li> </ul> <p><strong>Please state clearly in the finance section that the funding you are applying for is EPSRC Doctoral Landscape Award 2027/28: Mechanical Engineering.</strong></p> <p>You will be required to provide a personal statement which outlines your interest in the project you are applying for, why you have chosen it and how your skills map onto the requirements of the project. </p> <p><strong>Please note that you must provide the following documents in support of your application by the closing date of 18 November 2026 or at the point you submit your application:</strong></p> <ul> <li>Full Transcripts of all degree study or if in final year of study, full transcripts to date including grading scheme</li> <li>Personal Statement outlining your interest in the project</li> <li>CV</li> </ul> <p>If English is not your first language, you must provide evidence that you meet the University's minimum English language requirements (below).</p> <p><em>As an international research-intensive university, we welcome students from all walks of life and from across the world. We foster an inclusive environment where all can flourish and prosper, and we are proud of our strong commitment to student education. Across all Faculties we are dedicated to diversifying our community and we welcome the unique contributions that individuals can bring, and particularly encourage applications from, but not limited to Black, Asian, people who belong to a minority ethnic community, people who identify as LGBT+ and people with disabilities. Applicants will always be selected based on merit and ability.</em></p>

Applicants to research degree programmes in the School of Mechanical Engineering should normally have at least a first class or an upper second class British Bachelors Honours degree (or equivalent) in an appropriate discipline. Applicants are advised to check with the relevant School prior to making an application. Applicants who are uncertain about the requirements for a particular research degree are advised to contact the supervisor or Admissions Team prior to making an application.

The minimum English language entry requirement for research postgraduate research study is an IELTS of 6.0 overall with at least 5.5 in each component (reading, writing, listening and speaking) or equivalent. The test must be dated within two years of the start date of the course in order to be valid. Some schools and faculties have a higher requirement.

<p>A highly competitive EPSRC Doctoral Landscape Award (DLA) providing full academic fees, together with a tax-free maintenance grant at the standard UKRI rate (currently £21,805 in academic session 2026/27) for 3.5 years and rising annually, in line with standard UKRI rates. Training and support will also be provided.</p> <p>This opportunity is open to UK applicants only. </p> <p><br /> <strong>Competition funded  </strong></p> <ul> <li>"Competition funded" means that we advertise a larger number of projects than available awards. Not all projects advertised for this funding opportunity will receive funding. The selection panel will consider all applications received across the full range of advertised projects and select the awardee/s based on the strength of their application. </li> </ul> <p><br /> <strong>Eligibility Criteria </strong></p> <ul> <li>Applicants must be eligible to pay fees at the Home (UK) rate.</li> </ul> <p class="MsoNoSpacing"><br /> <strong>Other Conditions</strong></p> <ul> <li class="MsoNoSpacing">Candidates who have previously been awarded a PhD or are currently registered on a PhD are excluded from applying. Those who were previously studying for a PhD but did not complete may be considered. </li> <li>Awards must be taken up by 1st October 2027.</li> <li>Applicants must live within a reasonable distance of the University of Leeds whilst in receipt of this scholarship.</li> </ul> <p><br /> If you are unsure whether you are eligible for UK fees/funding, please see our <a href="https://www.leeds.ac.uk/undergraduate-fees/doc/fee-assessment">fee assessment page.</a></p> <p> </p>

<p>For further information please contact the PGR Admissions Engineering and Physical Sciences team on this email address: <a href="http://phd@engineering.leeds.ac.uk/">phd@engineering.leeds.ac.uk</a></p> <p>If you are interested in this project or have any questions, please contact the project supervisor <a href="https://eps.leeds.ac.uk/mechanical-engineering/staff/12256/dr-masoud-jabbari">Dr Masoud Jabbari</a> on this address: <a href="mailto:M.Jabbari@leeds.ac.uk">M.Jabbari@leeds.ac.uk</a></p>