HARMONY project aims at strengthening the independency and the competitiveness of European industry, enabling a resilience value chain of raw materials by developing and validating at pilot scale an innovative, green and safe closed-loop recycling process of Rare Earth Elements (REEs) from End-of-Life (EoL) NdFeB permanent magnets. The recycling loop encompasses the collection and dismantling of EoL NdFeB magnets and WEEE scrap, the recovery of REE metals through an indirect recycling process, the production of recycled NdFeB powder via three direct recycling methods, the manufacturing of magnets from the recycled powder, and the validation of the recycled magnets in end-user applications. Collection and recycling steps will be implemented in 8 pilot plans reaching a final TRL of 6-7. The combination of direct and indirect recycling technologies will allow dealing with any scrap containing NdFeB in any form (sintered or bonded magnets). The recycled NdFeB magnets will be used in the same applications as the magnets made from primary powder, since they will exhibit comparable properties. Additionally, they will be recyclable via the same routes. A Dissemination, Exploitation, and communication Master Plan (DECMP) will be developed to maximize the impact beyond the lifetime of HARMONY project. HARMONY will build upon existing standards during the development of the novel products, ensuring compatibility with market conditions and increasing transparency for prospective customers. The economic, environmental and social viability of these processes will be demonstrated via Life Cycle Assessment (LCA), Social Life Cycle Assessment (S-LCA) and Life-Cycle Cost Analysis (LCCA). Furthermore, social innovation including citizen dialogue, policy issues, standardization and ethics will be considered to overcome the non-technological barriers that make difficult to introduce these novel technologies at the short term in the market.

To tackle its (critical) raw material dependency, Europe needs comprehensive strategies based on sustainable primary mining, substitution and recycling. Freshly produced flows and stocks of landfilled industrial residues such as mine tailings, non-ferrous slag and bauxite residue (BR) can provide major amounts of critical metals and, concurrently, minerals for low-carbon building materials. The European Training Network for Zero-Waste Valorisation of Bauxite Residue (REDMUD) therefore targets the vast streams of new and stockpiled BR in the EU-28. BR contains several critical metals, is associated with a substantial management cost, whereas spills have led to major environmental incidents, including the Ajka disaster in Hungary. To date, zero-waste valorisation of BR is not occurring yet. The creation of a zero-waste BR valorisation industry in Europe urgently requires skilled scientists and engineers, who can tackle the barriers to develop fully closed-loop environmentally-friendly recovery flow sheets. REDMUD trains 15 researchers in the S/T of bauxite residue valorisation, with emphasis on the recovery of Fe, Al, Ti and rare earths (incl. Sc) while valorising the residuals into building materials. An intersectoral and interdisciplinary collaboration of EU-leading institutes and scientists has been established, which covers the full value chain, from BR to recovered metals and new building materials. Research challenges include the development of efficient extraction of Fe, Al, Ti and rare earths (incl. Sc) from distinct (NORM classified) BRs and the preparation of new building materials with higher than usual Fe content. By training the researchers in pyro-, hydro- and ionometallurgy, electrolysis, rare-earth extraction and separation technology, inorganic polymer and cement chemistry, Life Cycle Assessment (LCA), NORM aspects and characterisation, they become the much needed scientists and engineers for the growing European critical raw materials industry.

EURO-TITAN will be a pioneer in unlocking continuous Ti resources from metallurgical waste streams from alumina and Ti-dioxide production, developing 54 ktpy of Ti metal making Europe totally independent from Russian Ti-metal sponges imports crucial for alloy production in the transport and medical sectors. On this purpose an industrial driven consortium gaining experience from previous and ongoing projects for metals exctraction from industrial wastes (Scavanger,Scale, Scale Up,Valore) will develop a >90% lower CO2 emission (compared to the conventional Kroll process which produces 10tn per tn of Ti) green hydrogen sourced(ref-hyd) direct Ti reduction process will be scaled to demonstration in the industrial environment at the Bosnian Al-plant to produce tailor-made Ti-metal products for ingots or alloying. Our Ti-metal price will be 15% lower compared to imported ones (rough estimate 6800 €/t Ti compared to current prices from Russia and China at 8500 €/t). Process optimization will be achieved through integration of inline-real time data monitoring, establishing repository of high-quality and trusted datasets, and embedding Artificial Intelligence. This will lead to a 10% reduction of on-site energy and water consumption, while at the same time minimizing production interruption. Finally, circularity is ensured, as the remaining residues are converted into innovative (30% lower co2 emissions compared to cement based) construction materials while water will be recycled, and excess heat energy will serve local households.

Nature uses foam or sponge-like structures in various organisms for purposes like shock absorption, noise reduction, and vibration compensation in a remarkable example of evolutionary adaptation and functional design. On the other hand, many products still rely on non-sustainable materials of fossil-based origin, for example foams and elastomeric used for vibratory motion, sound, harshness, energy, and shock-impact absorption in industries such as automotive, aerospace and marine. Example of such Noise Vibration and Harshness (NVH) materials are rubber and engineering resins. Bio.3DGREEN develops and demonstrates a novel manufacturing approach for a cost-effective bio-inspired platform of bio-based components based on graphene foam (GF) to meet the industrial needs, i.e. vibration, sound and shock-impact absorption and durability in extreme conditions. Bio.3DGREEN democratizes graphene technology and enables the unscalable fabrication of graphene-based components of complex geometries to be demonstrated at TRL 6 through a high throughput, laser-based Additive Manufacturing (AM) procedure. The procedure is bio-inspired, mimicking structures such as the human bone, and is based solely on bio-based graphene system with vegetable oil as the raw material, resulting in carbon-positive manufacturing of the new components. Bio.3DGREEN demonstrates the superior bio-based GF parts in four different industries, aiming to drive the optimization of the new manufacturing approach through an application-driven approach: Automotive suspension systems & isolation panels, aerospace applications and quiet shipping. Bio.3DGREEN achieves a multi-disciplinary approach to develop, optimize, and improve smart manufacturing application-driven, bio-based GF components, also considering the performance of current materials used, their cost, market size, wastage and recyclability, sustainability of manufacturing process, inclusion in Europe’s circular economy and LCA, LCC aspects.