PRIM-ROCK addresses process efficiency through a multifaceted strategy addressing industrial processes from input to output, supported by an ambitious digital framework and transversal supporting activities. In particular, advanced techniques for the pre-processing of the raw material will be deployed to enhance its efficiency according to the requirements of the process, supplemented by simulations and decision support systems to increase the operational limits of flexibility in the feedstock domain. Additionally, the process intensification component of the project will design, develop, and validate innovative and efficient processes, as well as optimizing the existing ones. The aim is to develop a portfolio of technologies to a higher resource efficiency and lower level of GHG emissions of extractive industries. The project will focus on improving the resource efficiency of the calcination and roasting processes, that are commonly used in the mineral and cement industries. To this end, process simulations in collaboration with AI data-driven models will be utilized and a digital twin for each process will be developed. Finally, waste reduction and re-utilization strategies will be investigated targeting to the real-time processes’ adjustment capabilities to feedstock changes and tighter processing control solutions. All these components will be supplemented by transversal supporting activities, such as technoeconomic assessment, LCA, standardization etc. The PRIM-ROCK solutions will be demonstrated in 3 different ASPIRE sectors, namely Minerals (magnesite, laterite), Cement (limestone) and Non-ferrous metals (sphalerite, chalcopyrite). The consortium is composed of 7 SMEs along with 6 RTDs, 3 universities and 5 large enterprises, working together to achieve over 30% resource efficiency enhancement in each use-case, 770ktCO2 averted, productivity increase in the range 9-16% and more that 1,360 new jobs by 2033.

Global alumina production capacity is forecast to grow by 30% over the next ten years. Unfortunately, Europe cannot keep the competition and is highly dependent on imported alumina and bauxite. ENSUREAL project’s main objective is to decrease this dependence and characterise all the streams of the alumina industry in order to valorise them and make the European aluminium industry more competitive at a global scale. In order to do so, ENSUREAL addresses the production of alumina of the aluminium production sector, through the introduction of a new technology (Pedersen process) that improves the process’ yield and its energy and environmental performance. Moreover, ENSUREAL’s consortium proposes a new value chain that takes into account all the streams as valorisable products across the aluminium supply chain and introduces the foundry and the agricultural sector. A call for transparency (no-more-black-boxes) and thus a deeply cross-sectorial initiative. More specifically, ENSUREAL brings together the aluminium sector (Aluminium of Greece), the foundry sector (Odlewnie Polskie S.A., Poland), the agricultural sector (Luvena S.A., Poland) and lime producers (CaO Hellas, Belgium), in order to demonstrate the new technologies and approaches proposed. The innovative character of the project is brought by major players in R&D, such as SINTEF, NTUA and NTNU. Outotec and SMS group bring outstanding engineering and process expertise. Furthermore, 3 SMEs will help define and optimise the bauxite scenario in Europe (AdMiRIS), develop ENSUREAL's business case (ITRB) and study the upscaling of the process for future commercial prospects (KON Chem). Last but not least, clustering with other EU initiatives, including other SPIRE projects, will be paid special attention in order to promote a transparent approach of development that show the aluminium producers in Europe all the benefits of implementing the ENSUREAL process once it is demonstrated.

Decarbonization of processes, scarcity of raw materials and Europe independence on key resources, valorisation of industrial waste are all key and strong challenges the EU metallurgy industry is facing and will have to deal with in the next decades to remain sustainable while keeping its economic competitiveness. This is particularly true for the manganese (Mn) & Mn ferroalloys industries. HAlMan represents a game changer in the metallurgical industry in view of developing sustainable processes with low carbon footprint, low energy consumption, no solid waste generation, valorisation of secondary raw materials from mining and metallurgical industry. HAlMan will demonstrate at TRL 7 an integrated process to produce Mn metal and Mn alloys from Mn ores and Mn-containing waste by using hydrogen and secondary aluminum (Al) sources as reductants. As metallurgical processes have large share in CO2 emission, decarbonization in metallurgical industry is essential to operate metal production in Europe. The benefits of the HAlMan innovative process will go beyond Mn and Mn Ferroalloys industries, and it presents a unique intersectoral approach in circular economy where: • Al-containing dross/scrap, and waste from ferromanganese industry are valorised to produce directly new Al-Mn master alloys for Al and Steel industries • metallurgical grade alumina (the feedstock for Al production, produced almost exclusively from Bauxite which is a CRM for EU) is produced via a zero-carbon footprint process • the extraction of critical raw materials, including REEs, from the alumina production process by-products will be demonstrated • the production of manganese oxide and cell fabrication for lithium-ion battery applications will be demonstrated. Additionally, HAlMan project studies heat and hydrogen recovery from process gas to improve process economy and yield. Significant activities on Life cycle assessment, Business development, dissemination and communication will be carried.

Surface coatings are essential for protecting materials and enhancing their functionality, but the reliance on fossil resources necessitates safer, sustainable alternatives that maintain high performance while reducing environmental impact. To address these challenges, BLUECOAT will develop 12 safe, sustainable, bio-based, and low-carbon emission coating formulations for the marine, textile, and construction sectors that are challenging and demanding conditions for coatings. The project will explore 4 bio-based feedstocks: bio-derived polymers, natural fibres, bioplastics, and plant-based proteins, to develop 6 optimized coatings consisting of bio-based PU, bio-based silicone, PLA, natural fibres with antimicrobial agents (such as chitosan and curcumin), and encapsulates with Phase Change Materials (PCM). BLUECOAT formulations will cut GHG emissions by 45% and minimize Volatile Organic Compounds (VOC) while delivering superior performance under industrially relevant conditions (TRL 5). BLUECOAT solutions will provide antifouling and anti-corrosion protection for ship hulls, weatherproof, antimicrobial, and durable features for outdoor technical garments, and flame-retardant and antifungal for insulation boards in marine, textile, and construction sectors, respectively. The BLUECOAT’s vision is to establish a suite of comprehensive Safe-and-Sustainable-by-Design criteria guiding the development of bio-based coatings throughout their lifecycle, emphasizing circularity, energy and resource efficiency. The project will conduct the ex-post environmental assessment, techno-economic feasibility of scaling potential products, socioeconomic impact analysis for ensuring sustainable market adoption and long-term viability of the developed coatings. It will also explore End-of-Life strategies like biodegradability and recycling to extend material utility and support sustainable practices.

According to today’s practice, wood waste is roughly classified into three or four classes, depending on the country. The most polluted grade, often referred to as grade C or AIII/AIV, consists of preservative-treated wood, i.e. wood that has been impregnated with chemicals (pesticides, biocides and fungicides) to enhance its bio-resistance. Grade C or AIII/AIV is not currently recycled. The increased use of wood as encouraged by initiatives like the New European Bauhaus is likely to require additional volumes of preservative-treated wood. Even though such treatments extend the service life of wood products, they will still eventually become waste and must be dealt with. Wood preservation compounds pose a significant threat to not only the environment but also to human health, and therefore it is needed to develop efficient remediation technologies. At the same time, current recycling processes are greatly complicated by the presence of pollutants (chemical treatment products, heavy metals), which calls for further research on cleaning methods. As grade C comprises of several types of wood types and products, along with different levels of contamination, this poses a complex problem that needs action from both the circular economy and non-toxic environment fields. The development of an automated on-line characterization system to distinguish chemically contaminated wood waste has become a high priority. Gaps in existing regulations should be considered as may not fully support the use of upcycled wood materials from such waste streams. IN2WOOD proposes a multi-dimensional cascade approach for highly polluted post-consumer wood waste via a series of seven Pilot Validation Trials (PVTs) with aim to reduce the demand for virgin materials, reduce unsustainable options such as landfilling or incineration, and support the transition towards a circular economy by developing new value-added products from clean secondary materials.