The project GR4FITE3 aims to reach Graphite Resilience For lithium-Ion baTtery anodes through a sustainable European End-to-End supply chain. This supply chain includes environmentally responsible European mining of natural crystalline flake graphite from Europe’s largest natural graphite resource, highly innovative, continuous and low energy input upgrading of the mined ore, adding recycled and fully repaired for reuse synthetic graphite and optionally silicon nanoparticles to compose a unique anode active material’s particle architecture, making the high density anodes, creating the cells, developing battery modules, certifying the lithium-ion batteries for safety and viability, and ultimately using these products by the OEMs including an established European electric bus manufacturer and a utility grid developer, among others. The purpose of GR4FITE3 project is to demonstrate the creation of a sustainable supply chain for the European industrial graphite and carbon products for specific use as anode active materials in Lithium-Ion batteries designed for applications in electric vehicles and power sources for utilities, such as solar and wind farms. This project is going to combine the efforts of 10 partner organizations from six European nations, employing both industry and academia. There are also four OEMs and five supporting organizations who have expressed their interest in tracking project’s progress and part-taking in a tangible manner in commercialization efforts associated with GR4FITE3 projects’ outcomes. With this larger group of stakeholders, the project spreads its reach to as many as ten countries and three continents, ensuring its global outreach from the very start.

Specific raw materials become increasingly important to manufacture high level industrial products. Especially electronic equipment contains precious metals and a series of strategic raw materials. To date the material specific recycling is focused on mass stream concepts such as shredder processes and metallurgy to extract the high-value metallic constituents, i.e. copper, gold, silver. However, a series of critical elements cannot be recovered efficiently or is even lost in dust or residual fractions. The goal of ADIR is to demonstrate the feasibility of a key technology for next generation urban mining. An automated disassembly of electronic equipment will be worked out to separate and recover valuable materials. The concept is based on image processing, robotic handling, pulsed power technology, 3D laser measurement, real-time laser material identification (to detect materials), laser processing (to access components, to selectively unsolder these; to cut off parts of a printed circuit board), and automatic separation into different sorting fractions. A machine concept will be worked out being capable to selectively disassemble printed circuit boards and mobile phones with short cycle times to gain sorting fractions containing high amounts of valuable materials. Examples are those materials with high economic importance and significant supply risk such as tantalum, rare earth elements, germanium, cobalt, palladium, gallium and tungsten. A demonstrator will be developed and evaluated in field tests at a recycling company. The obtained sorting fractions will be studied with respect to their further processing and recovery potential for raw materials. Refining companies will define requirements and test the processing of sorting fractions with specific material enrichments. An advisory board will be established incorporating three telecommunication enterprises.

Envisioned battery demand of 735 GWh for electric mobility by 2025, escalating to a projected 125 million Electric Vehicles (EVs) by 2033, fuels our impetus for innovation. However, these prospects are marred by real safety concerns, evidenced by 2 harrowing ship fires involving luxury EVs, despite adherence to the most stringent safety protocols. SAFELOOP is a collaborative effort involving 15 entities from 11 countries, representing a blend of research, manufacturing, and business across Europe. Transatlantic partners are joining forces to bolster competitive material-level technologies and supply chain logistics. Key goals include securing strategic raw material feedstock, reducing reliance on Asian supply chains, intensifying environmental sustainability, optimizing energy-efficient processing, and demonstrating technological leadership. SAFELOOP’s focal point is Gen3 EU EV Li-Ion Battery (LIB) safety, encompassing the entire life cycle of LIBs within EVs. Safety is considered in a broader sense, not just at a cell level, while the latter remains a key pillar of the research at hand. To name a few, material handling, component processing, battery manufacturing, testing, transport, maintenance, and recycling of active materials are considered. A Eurocentric supply chain for EV-grade battery materials will be established, minimizing the environmental and cost impact of long-distance transportation. SAFELOOP ensures that batteries and their components adhere to EU safety and environmental regulations. Beyond enhancing EU battery safety, the project seeks to develop the world's first EV-rated LIB using up to 25% recycled and fully rejuvenated battery-active materials. This initiative paves the way for an ambitious industry-wide recycling target of 90% within the next decade, akin to today's lead-acid battery industry's 95% recycling rate. These ecologically responsible solutions address key aspects of automotive battery safety within the EU and beyond.