CRUSADE upscales novel technologies to TRL7 integrated in a universal hydrometallurgical method to recycle up to 500 tn/year of spent automotive components (autocatalysts, fuel cells, batteries and printed circuit boards) from end-of-life vehicles and recover ca 40 tn/year of critical raw materials (Cu, C, Co, Mn, Ni, Pt, Pd, Rh, Li, Ru) at commercial specifications. The project leverages predeveloped technologies to establish a market ready pilot unit utilising novel concepts for material tracing using blockchain (AKO, SAISLAB, ENTE) and pan European collection network establishment from the pioneers of the automotive components manufacturers (SUN, ADV, CRF, MONO, ACU) which guarantee the long term sustainable operation of the unit. The material processing covers the whole chain from pre-treatment using validated technologies from the experts on the CRMs recovery (MONO, TUBAF, KUL) and upstream processing using a microwave assisted leaching methodology enabling a 15-80% lower CO2 emission process (depending on the feed), compared to commercial processing. High specification market ready materials are prepared as outputs of the project undergoing a downstream purification and recovery process using solvent extraction and electrowinning, guided by industrial standards for end-use applications, while validated and benchmarked during the course of the project in new automotive products. The processing is automated aiming to a 15% time reduction compared to current processes with the use of an industrial robot and artificial technology guiding the sorting and the hydrometallurgical treatment (Industry 4.0 concept). The materials are commercialised at 15% lower price compared to market standards due to the automated innovative cost efficient processing, CAPEX/OPEX reaching max 70% of product cost (average 30% gross profit margin depending on feed).

Europe is on the need of Critical Raw Materials (CRMs) to secure its green energy transition and achieve climate neutrality by 2050. PV panels for clean energy generation, and batteries for energy storage are key components for the green energy transition but heavily depending on CRMs. However, as the PV and EV markets were developing fast in the last decade in Europe, significant amount of secondary EV batteries, and PV panels will be available for recycling. Traditional approaches that have been used so far for their recycling are focused on materials recovery, and less on the enormous potential for reuse in second life before recycling. Additionally, proposed recycling processes so far are still suffering from several issues related to purity and efficiency of the processes as well as high cost and environmental aspects. The overarching aim of the SOLMATE project is to set up solid foundations of a new industrial value chain for the sustainable reuse and recycling of PV solar panels and EV batteries in interesting emerging markets and high added value applications. The main objectives of SOLMATE are on one hand i) to develop and demonstrate viable and guaranteed low-cost decentralised energy systems for different emerging markets and business cases based on the reuse of batteries from EoL EV and used PV solar panels (i.e., repowering from PV farms), and on the other hand, ii) to demonstrate low cost and environmentally friendly technologies for improving the purity and increasing the recovery of raw materials (especially critical raw materials) from EoL EV batteries and PV that cannot be reused. SOLMATE is designed to be fully aligned with the waste hierarchy principles as indicated in the Waste Framework Directive (Prevention, Reuse, Recycling, Recovery, Disposal).

PEACOC will showcase a first-of-a-kind economically and environmentally viable pre-commercial metallurgical system for recovering Precious Metals (PMs) (i.e. Platinum Group Metals (PGMs) identified as critical raw materials by the European Commission (EC), as well as gold (Au) and silver (Ag)), highly important for the EU economy, from a wide variety of abundant end-of-life (EPEACOC will showcase a first-of-a-kind economically and environmentally viable pre-commercial metallurgical system for recovering Precious Metals (PMs) (i.e. Platinum Group Metals (PGMs) identified as critical raw materials by the European Commission (EC), as well as gold (Au) and silver (Ag)), highly important for the EU economy, from a wide variety of abundant end-of-life (EoL) products in Europe. The concept is mainly based on previously developed recovery and refining technologies to TRL 5 in the PLATIRUS Research and Innovation project (Micro-Wave assisted leaching and Gas Diffusion Electrocrystallization GDEx), which were flagged by the Innovation Radar initiative of the EC as excellent innovations and showed a significant cost reduction and lower environmental impact compared to state-of-the-art hydrometallurgical processes as will be shown throughout the proposal. The PEACOC system will be demonstrated at pre-commercial scale at TRL7 with capacity to treat ~50t of PMs concentrates/year i.e., with a recovery capacity of i)2 kg PGMs/week from spent autocatalysts (containing ~2.5kg PGMs/t), ii) 0.5-1 kg Au/week from Printed Circuit Board Assembly (PCBA) with a focus on low and medium grade PCBA (containing 20-100 g Au/t) that are currently poorly valorized in industrial smelting processes due to low PM concentrations, and iii) 10 kg Ag/week from EoL Photovoltaic (PV) panels (containing ~3-10 kg Ag/t) which will be an abundant resource in Europe in the coming few years. The project will demonstrate the production of PMs at a profit margin up to 80% with respect to current PMs market prices.

The CROCODILE project will showcase innovative metallurgical systems based on advanced pyro-, hydro-, bio-, iono- and electrometallurgy technologies for the recovery of cobalt and the production of cobalt metal and upstream products from a wide variety of secondary and primary European resources. CROCODILE will demonstrate the synergetic approaches and the integration of the innovative metallurgical systems within existing recovery processes of cobalt from primary and secondary sources at different locations in Europe, to enhance their efficiency, improve their economic and environmental values, and will provide a zero-waste strategy for important waste streams rich in cobalt such as batteries. Additionally, CROCODILE will produce a first of a kind economically and environmentally viable mobile commercial metallurgical system based on advanced hydrometallurgical and electrochemical technologies able to produce cobalt metal from black mass containing cobalt from different sources of waste streams such as spent batteries and catalysts. The new established value chain in this project will bring together for the first time major players who have the potential of supplying 10,000 ton of cobalt annually in the mid-term range from European resources, corresponding to about 65% of the current overall EU industrial demand. Therefore, the project will reduce drastically the very high supply risk of cobalt for Europe, provide SMEs with novel business opportunities, and consolidate the business of large refineries with economically and environmentally friendly technologies and decouple their business from currently unstable supply of feedstocks.

The overall objective of NONTOX is to increase the recycling rates of plastics waste containing hazardous substances by developing and optimising recycling processes to produce safe and high quality secondary plastic materials and by optimising the overall process economics by integration. Increasing recycling rates is crucial for the implementation of a circular economy as clearly stated in the EU Plastic Strategy. NONTOX focuses on the removal of hazardous and undesired substances from plastic waste taking into account the whole value chain: sorting and pre-treatment techniques, recycling technologies but also post-treatment techniques. Valorisation of by-products and removed substances is also considered to enhance potential applications. NONTOX will target material recovery of plastics originating from WEEE, ELV and C&DW streams containing hazardous additives or undesired compounds such as flame-retardants, stabilizers, fillers, etc. Main secondary plastic outputs will include for example, ABS, EPS, PS, HIPS, PE, PP. The market for these polymers is massive as together they represent about half of the EU demand for plastics and yet a significant portion of these valuable plastics is landfilled or incinerated. NONTOX will further develop two different technologies (Extruclean and CreaSolv®) to remove hazardous substances from aforementioned plastic waste streams, allowing for increased recycling rates. NONTOX will also improve knowledge and state of the art concerning pre-treatment and sorting of plastic waste containing hazardous substances. Thermochemical conversion of non-target plastics and side streams from the main recycling processes will be investigated to increase system efficiency by integration and widen the range of final products and applications. NONTOX is conceived by a multidisciplinary consortium including internationally renowned RTOs, universities, key industrial partners and recyclers as well as product design experts.