Breaking batteries better: the science of smarter shredding

About the Project

When Li-ion batteries are recycled at industrial scale, the first step is shredding. What comes out, a mixture called "black mass", determines everything that follows, from hydrometallurgical processing to the feasibility of direct recycling. Yet there is a knowledge gap about what happens inside the shredder, and how processing conditions shape the materials we recover.

This PhD project will investigate how the state of charge of cells and the stabilisation method used during shredding (inert gas +/- water mist/ spray/ submersion) affect the separability, morphology, chemistry, and purity of active materials across multiple cell chemistries and formats. You will use a unique instrumented shredder capable of safely processing charged cells, and characterise the resulting materials using electron microscopy, tomography, and synchrotron techniques at Diamond Light Source and ESRF. You will also develop machine learning approaches to handle the large imaging datasets generated. No prior ML experience is required, but a willingness to learn is.

The goal is to close the knowledge gap between controlled single-cell abuse tests and the messy reality of industrial shredding, and to establish which conditions produce materials clean enough for direct recycling. Your findings will directly inform the design of safer, more efficient recycling processes.

The project includes a 3-month placement at Recyclus Group in Wolverhampton, the UK's first industrial-scale Li-ion battery recycling plant. You will gain hands-on experience of commercial recycling operations and work alongside their research team on an industrially relevant project.

This PhD is supervised by Dr Rob Sommerville and Dr Phoebe Allan, and is based in the Energy Materials Group within the School of Metallurgy and Materials at the University of Birmingham. The group comprises around 40 researchers working across Li-ion, Na-ion, and other energy storage systems, with dedicated facilities for safely dissecting, characterising, shredding, and recycling battery materials. The project is supported by the Faraday Institution and aligned with the ReLiB project.

As a Faraday Institution PhD researcher, you will receive a tax-free UKRI stipend with tuition fees covered, plus £2,000 per year for training and consumables. You will also have access to the Faraday Institution PhD Training Programme (valued at approximately £5,000 per year), which includes networking events, industry visits, mentorship, internships, and skills development opportunities designed to support your career beyond the PhD.

This position is open to UK home students only (UK nationals or those with settled status). Candidates must have at least a 2(i) in an Engineering or Scientific discipline, or a 2(ii) plus MSc or equivalent.

The University of Birmingham values the diverse backgrounds, perspectives, and experiences of its community and is committed to building an inclusive research environment. Applications are particularly encouraged from women and minority ethnic candidates, who remain under-represented in this field.

To apply, please complete both of the following steps:

1. Submit a Faraday Institution expression of interest form: https://www.surveymonkey.com/r/XL23CSF
2. Send a CV and cover letter summarising your research interests and suitability for the position to R.Sommerville@bham.ac.uk.

Feel free to get in touch with any queries in advance. Start date: 1st October 2026.