In the context of increasing global battery use, developing sustainable, safe and efficient processes is a tangible issue to further enhance circular economy and strategic autonomy of the European Li-ion batteries value chain, in line with the battery partnership’s objectives launched under Horizon Europe. RESPECT main objective is to develop a global process encompassing a process-chain flexible enough to treat all kind of batteries in closed loop, considering the variability of Li-ion batteries chemistries (NMC, LFP, NCA, LMO) , applications (EV and ESS) and states (aged, damaged, EoL, production scraps) up to date not covered by any process on the State of the Art. RESPECT addresses two recycling routes: full hydrometallurgy and direct recycling and an improved Life Cycle Assessment of each recycling segment to lower emissions and reduce secondary pollution, safety and health risks. RESPECT will aim to design and validate the recycling processes up to pilot scale to recovering the highest amount of resources, including CRMs and active materials present in the batteries to closing the loop by their reuse in cathode and anode materials for new batteries. Socio-economic, as well as sustainability aspects will be covered throughout the project. To ensure a successful project implementation, knowledge sharing on Li-ion battery green recycling processes will be fostered, based on the engagement with relevant international stakeholders and experts through the advisory board. Based on a solid and interdisciplinary consortium of partners covering the whole value chain, RESPECT seeks high recovery rates (for Li, Mn, Co, Ni or graphite) with low environmental impact and strong energy savings, in accordance with the European Green Deal and the proposed Battery Regulation.

The aim of ITERAMS is to develop a proof of concept for more environmentally friendly and economic mine site operations, in Europe and globally. For that, the ITERAMS project focuses on the isolation of process waters completely from the adjacent water systems. This will require development of new methods for optimising and controlling water qualities at each process step. As a bonus, this will also facilitate the recovery of additional valuable constituents. The ITERAMS project will develop research and dimensioning protocols suitable for use at the mines processing different ores. In this context, validation of the concepts will have an essential role. In the planned project, it will be performed at selected mine sites processing sulphide ores, although the concepts will be generic and thus also suitable for other types of ores like gold, rare earth, and phosphate ores. The closure of water cycles at each process stage will inevitably increase their thermodynamical and kinetic unstability (as is also the case with conventional tailing ponds). In addition, water temperatures will also increase, causing higher bacterial growth, especially for iron and sulphur oxidising species. This will result in a dynamic situation that has never so far been worked on. The ITERAMS project will create new academic and industrial knowledge and capabilities to tackle such questions. The tightly closed water cycles can be realised only if the tailings can be filtered and stacked dry. ITERAMS will demonstrate the use of geopolymerisation to create water and oxygen tight covers on the deposited tailings. For that, the tailings streams will be modified for their easier geopolymerisation. The ITERAMS water and waste efficient methods will be validated at mine sites in Finland, in Portugal and additionally either in Chile or South Africa.

Global Manganese-alloys (Mn) are highly linked to the steel sector for key engineering applications in Europe. In 2017, Mn-alloy production was approx. 4 Mio tons, required 12,200 GWh electrical energy and emitted around 14.2 Mio tons of CO2. Therefore, an energy intensive and inherent cross-sectorial value chain that is, nowadays, led by the Asian market demand. PREMA is an ambitious initiative that aims at demonstrating an innovative suite of technologies (involving heat recovery and solar technologic approaches) that allow to pre-treat Mn ores, utilising more efficiently energy and material streams and decreasing direct and indirect CO2 emissions (along with SO2 and NOx). LCA and LCCA methodologies will be implemented from early stages to ensure the technical, economic and environmental viability of the solution across the whole Mn-alloys’ value chain. The vision of PREMA is thus to make the Mn-alloys sector in Europe more flexible, sustainable and attractive. In order to cover the whole value chain, t

SUPREME aims at optimizing powder metallurgy processes throughout the supply chain. It will focus on a combination of fast-growing industrial production routes and advanced ferrous and non-ferrous metals. By offering more integrated, flexible and sustainable processes for powders manufacturing and metallic parts fabrication, SUPREME enables the reduction of the raw material resources (minerals, metal powder, gas and water) losses while improving energy efficiency, production rate and CO2 emissions, into sustainable processes and towards a circular economy. To achieve this goal, an ambitious cross-sectorial integration and optimization has been designed between several powder metallurgy processes: gas and water atomization as well as ball milling for metal powder production, additive manufacturing and near-net shape technologies for end-parts fabrication. Quality and process control will be developed to monitor KPI, based on eco-innovation approach, to demonstrate the optimization of material and energy use. 4 demonstrators will be proposed at each step of the value chain in real industrial setting and ready for business exploitation at TRL 7: mineral concentration, metal powder manufacturing, metal part manufacturing and end-product that will validate a global optimization of more than 25% on material yield losses, more than 10% on energy efficiency, more than 10% on production rate and beyond 30% of CO2 emissions. SUPREME has gathered an outstanding consortium of 17 partners from 8 countries, represented by 11 companies including 6 SMEs that will ensure a successful implementation towards market applications. 5 applications sectors are targeted: automotive, aeronautics, cutting tools, molding tools and medical. The process key differentiation advantages will bring modularity, flexibility and sustainability to powder metallurgy and will reduce the total cost breakdown of these technologies, boosting their adoption by industry.