Modelization of a Taylor-Couette reactor for application in critical metal recovery from recycled batteries

IFP Energies nouvelles (IFPEN) est un acteur majeur de la recherche et de la formation dans les domaines de l’énergie, du transport et de l’environnement. De la recherche à l’industrie, l’innovation technologique est au cœur de son action, articulée autour de quatre priorités stratégiques : Mobilité Durable, Energies Nouvelles, Climat / Environnement / Economie circulaire et Hydrocarbures Responsables.

Dans le cadre de la mission d’intérêt général confiée par les pouvoirs publics, IFPEN concentre ses efforts sur :

• l’apport de solutions aux défis sociétaux de l’énergie et du climat, en favorisant la transition vers une mobilité durable et l’émergence d’un mix énergétique plus diversifié ;
• la création de richesse et d’emplois, en soutenant l’activité économique française et européenne et la compétitivité des filières industrielles associées.

Partie intégrante d’IFPEN, l’école d’ingénieurs IFP School prépare les générations futures à relever ces défis.

Modelization of a Taylor-Couette reactor for application in critical metal recovery from recycled batteries

Battery recycling is becoming more and more important, particularly for critical metals recovery (lithium, nickel, cobalt, copper, …), in a general context of rarefaction of these critical metals. Besides, in a tense international context, developing recycling processes is particularly strategic. IFPEN develops recycling processes using the hydrometallurgical route.

This approach involves multiple steps, starting with leaching, where shredded batteries are mixed with an acid solution to transfer metals into soluble forms. These metallic solution ions can then be purified and subsequently used to synthesize cathode active material precursors (PCAM) through co-precipitation, thereby fostering a circular economy.

A Taylor-Couette reactor (TCR) is used for PCAM synthesis. In TCRs, the hydrodynamics is precisely controlled from the laminar to the turbulent regime. Besides, TCR conducts to better particles nucleation and agglomeration, and thus to a better quality of PCAM synthesis.

Description :

The TCR experimental pilot unit is not yet available at IFPEN. In the meantime, the overall objective of this internship is to develop a numerical twin model for the simulation of TCR in the liquid/solid (L/S) particulate flow regime. The general approach will rely on developments based on the open-source software OpenFOAM. OpenFOAM is free of charge and provides full access to all its sources, making it a valuable and flexible platform for the implementation, testing and integration of new models.

After being trained to the OpenFOAM suite, this internship will have the following main objectives:

• Train on TCR meshing and rotating machines simulations, using single-phase flow solvers in a first place. Meshing will be done using available automatic tools, like blockMesh or Pointwise.
• Setup two-phase L/S simulations using a standard Euler-Euler approach.
• Explore the bibliography on solids nucleation and agglomeration models.
• Setup a population balance approach, based on the OpenQBMM open-source module.

Opportunity to continue with a PhD on the same subject, with both experimental and numerical aspects.

Required profile :

English or French, OpenFOAM, curiosity, enthusiasm, autonomy.

• Strong background in fluid mechanics and CFD, programming in C++ and shell script.
• Knowledge in chemical engineering would be a plus.

Additional information :

Workplace: IFPEN Solaize (South of Lyon) Transport: IFP Energies Nouvelles – Solaize is located 20 km south of Lyon. A personal mean of transportation is recommended but the site can be reached by public transportation as well (a shuttle between the train station of Feyzin or Metro B and IFPEN is available in the morning and afternoon). Remunerated internship