PhD on Investigation of iron powder from diverse feedstocks as a Circular Energy Carrier (CEC) focused on production process and combustion characteristics

Introduction

Join a pioneering project focused on finding the most suitable, economically efficient feedstocks for massive iron powder production to establish Metal-enabled Cycle of Renewable Energy (MeCRE)!

Job Description

One of the greatest challenges in the global energy transition is bridging the gap between society’s demand for continuous, reliable energy and the inherently intermittent and geographically scattered nature of renewable sources such as solar and wind. Iron powder is emerging as one of the most promising circular energy carriers due to its high energy density, carbon-free combustion, and excellent recyclability. Iron powder can be produced using green hydrogen and transported to end-users, where it is combusted with air to release energy. This combustion yields only solid iron oxide, which can then be collected, shipped back, and regenerated into iron fuel—thus completing the Metal-enabled Cycle of Renewable Energy (MeCRE), also known as the Iron Power Cycle.

To scale this cycle to a global level, a substantial supply of high-quality iron powder is essential. This PhD project focuses on identifying the most effective feedstocks and production methods for generating iron powders that can withstand repeated combustion and reduction cycles.

Your research will focus on:

(1) Developing H₂-based thermal reduction methods (and electrochemical reduction if needed) to convert various feedstocks—including iron-oxide ores, water treatment sludge, and electric arc furnace (EAF) dust—into iron microparticles (>10 μm).

(2) Investigating the first-cycle combustion performance of these powders, accounting for impurities inherited from their feedstocks. Key performance indicators include ignition temperature, micro-explosion behavior, emissions (gaseous and nanoparticulate), and oxidation degree.

The key responsibilities include:

• Conducting H₂-based thermal reduction experiments in a fluidized-bed reactor for iron ores and sludge; and developing leaching, sintering, and reduction procedures for EAF dust.
• Characterizing the produced iron powders using advanced analytical techniques to determine particle size, porosity, surface area, elemental and phase composition, and more.
• Performing single-particle combustion tests to evaluate ignition and explosion behavior.
• Conducting lab-scale combustion experiments to analyze emissions and overall combustion efficiency.
• Characterizing post-combustion residues to assess morphological changes and chemical composition.
• Disseminating your findings through high-impact journal publications and presentations at international conferences.

This position is part of the research project "From Powder Material Properties to Metal-enabled Cycle of Renewable Energy (PMP-to-MeCRE)", funded by the Dutch Research Council (NWO) under the Open Technology Programme. You will work at the intersection of materials science, chemical processing, and combustion technology, in collaboration with both academic and industrial partners, including Metalot, RIFT, Iron+, KWR, ArcelorMittal (France), and Companhia Siderúrgica Nacional (CSN, Brazil).

Why Join Us?

This PhD position offers a unique opportunity to contribute to pioneering research in the fast-emerging field of metal energy carriers. You will have access to state-of-the-art experimental facilities that support the entire Iron Power Cycle and play a key role in addressing one of the most pressing research questions: Which feedstocks are best suited for the scalable, circular production of iron fuel?

At TU Eindhoven (TU/e), we prioritize your academic and personal development. You’ll benefit from robust training programs, a collaborative and supportive research environment, and opportunities for international exposure.

Our research group, the Power and Flow Section in the Department of Mechanical Engineering, is recognized as a global leader in both the fundamental and applied aspects of Iron Power Cycle research. The team includes over 10 PhDs and postdocs and six faculty members with expertise ranging from computational modeling and experimental diagnostics to combustion physics and electrochemistry. As part of this dynamic group, you will receive strong mentorship and hands-on support to develop your skills and pursue your research goals.

Moreover, you will become an active member of the Eindhoven Institute for Renewable Energy Systems EIRES!

Project team

The PMP-to-MeCRE project is jointly led by Prof. XiaoCheng Mi, an expert in metal combustion, and Prof. Giulia Finotello, an expert in chemical processing for iron-oxide reduction, both from the Power and Flow Section at TU/e.

You will collaborate closely with:

• A fellow PhD researcher working on developing smart processes to enhance cycle performance of iron powders.
• A postdoctoral researcher focused on standardization and precision in powder material characterization.
• Industry engineers and R&D specialists from our consortium partners who are actively contributing to the large-scale realization of the Iron Power Cycle.

This collaborative structure ensures a well-rounded and impactful research experience.

Job Requirements

We are seeking a talented and motivated candidate with a strong academic background and a passion for research. Ideal applicants will meet the following criteria:

• Master’s degree in mechanical engineering, chemical engineering, or a closely related field.
• Solid foundation in thermo-fluid sciences and reactive flow systems.
• Hands-on experience with high-temperature experimental setups involving chemically reacting systems.
• Familiarity with materials characterization techniques (preferred but not required).
• Strong communication skills and the ability to work effectively in a multidisciplinary team.
• Proficiency in spoken and written English. 

Conditions of Employment

• A meaningful job in a dynamic and ambitious university, in an interdisciplinary setting and within an international network. You will work on a beautiful, green campus within walking distance of the central train station. In addition, we offer you: 
• Full-time employment for four years, with an intermediate assessment after nine months. You will spend a minimum of 10% of your four-year employment on teaching tasks, with a maximum of 15% per year of your employment. 
• Salary and benefits (such as a pension scheme, paid pregnancy and maternity leave, partially paid parental leave) in accordance with the Collective Labour Agreement for Dutch Universities, scale P (min. € 2,901 max. € 3,707).  
• A year-end bonus of 8.3% and annual vacation pay of 8%. 
• High-quality training programs and other support to grow into a self-aware, autonomous scientific researcher. At TU/e we challenge you to take charge of your own learning process. 
• An excellent technical infrastructure, on-campus children's day care and sports facilities.  
• An allowance for commuting, working from home and internet costs. 
• A Staff Immigration Team and a tax compensation scheme (the 30% facility) for international candidates. 

Information

Do you recognize yourself in this profile and would you like to know more? Please contact prof. XiaoCheng Mi (x.c.mi@tue.nl) and prof. Giulia Finotello (g.finotello@tue.nl). 

Visit our website for more information about the application process or the conditions of employment. You can also contact HR advice, HRadviceME@tue.nl or +31 40 2475902.

Are you inspired and would like to know more about working at TU/e? Please visit our career page.

Application

We invite you to submit a complete application by using the apply button. The application should include a:

• Cover letter in which you describe your motivation and qualifications for the position.
• Curriculum vitae, including a list of your publications and the contact information of three references.
• Brief description of your MSc thesis.

We look forward to receiving your application and will screen it as soon as possible. The vacancy will remain open until the position is filled.