INERRANT aims to drive genuine advancements for safe-and-sustainable-by-design materials, and eco-friendly processes, to ensure the economical and widespread utilization of safer LIBs tailored for the expanding electromobility applications in our modern society. To realize this, INERRANT is formulating a holistic approach to enhance safety performance, extend cyclability and operational lifespan, and improve fast charging, all while maintaining cost-effectiveness, energy, and power density, and avoiding dependence on Critical Raw Materials. The pivotal S&T challenges encompass: development of functional materials, design sustainable recycling processes and understanding of pertinent interfacial phenomena and degradation mechanisms. The project addresses current challenges for LIBs components related to (i) novel (nano)materials combinations for anodes and cathodes; (ii) smart-functioning separators; (iii) stimuli responsive electrolyte formulations; (iv) novel sustainable recycling processes to improve the purity of recovered materials. Novel electrochemical characterization methods and operando spectroscopies, both at the materials and component level, will be utilized. This includes the establishment of a metrological framework for traceable calibrations and the integration of machine learning methodologies for swift and early LIB cell aging predictions. Adopting fabrication methods that are inherently scalable, built upon existing pilot lines and proven safety testing, will facilitate a swift progression to Gigafactory-relevant scales. INERRANT will present a compelling business case and clear exploitation strategy, rooted in the consortium’s strategic insight, guaranteeing effective technology commercialization. This approach will support the economical and eco-friendly production of LIB cells and systems, tailored for e-mobility applications. INERRANT comprises a consortium of 11 partners from the European Commission and one associated partner from the USA.

Li-ion batteries are fundamental components for the energy transition of the European eco-system. Currently Europe lags behind Asia in terms of Li-ion battery cell manufacturing and more than 90% of the world's production takes place in China, Korea and Japan. To overcome this situation, there is an ambitious ramp-up plan of 25 new gigafactories in Europe with an expected value of €35 billion by 2030. However, in the ramp-up phase of these Gigafactories, a massive production of defects is expected, between 15% - 30%. The new European Gigafactories will also bring demand for €150 bn of battery manufacturing equipment. To support this demand, the EU production equipment industry needs to fill the current knowledge gap and gain competitiveness towards Asian providers, grounding on its world-wide leadership in high-tech, green technologies, enhanced by industry 4.0 digital solutions, exploiting the European Zero-Defect Manufacturing paradigm. The objective of BATTwin is to support this scenario by developing a novel Multi-level Digital Twin platform towards Zero-Defect Manufacturing in battery production, that will reduce defect rates in battery production lines. The solution integrates four pillars, namely (i) a multi-sensor data acquisition and management layer, supported by data semantics through a Digital Battery Passport data model, (ii) process-level digital twins, modeling the critical stages of electrode manufacturing, cell assembly and conditioning through multi-physics, data-driven and hybrid approaches, (iii) system-level digital twins, based on simulation and analytical modeling, (iv) user-centric, goal-driven digital twin workflows, increasing the explainability of digital twins and driving the user in system design and control. The approach will be tested in two industrial pilots producing different battery chemistries and geometries, validating the flexibility and scaleability of the approach towards Zero Defect European Gigafactories.

REVITALISE delivers a holistic solution for green, low-cost, and low environmental impact recycling of NMC (Hi-Ni), LFP and Na-Ion batteries, representing 85% of battery waste streams up to 2025. REVITALISE develops low-cost and green processes to recover a full range of battery materials, including NMC, LFP, Al, Cu, Li, graphite, fluorides, phosphates and plastics. Overall recycling rates of 91%+ will be proven at TRL4 for waste processed from post-production scrap and end-of-life battery black mass. REVITALISE will develop innovative pre-treatment technologies based on electrohydraulic fragmentation, ultrasonication and magnetic, and electrostatic separation that will achieve very high levels of material stream purity. This will enable commercially viable recycling of low-value parts. The approach will enable direct recycling of 40% of the cathode and anode active parts, with direct characterisation of the lithiation (or sodiation) being developed that will be used as a basis of a smart-reformation approach for reclaimed active materials. The remaining 60% being suitable for hydrometallurgical recycling based on leaching with green organic acids from food waste, such as vitamin C (ascorbates), vinegar (acetate) and citric acid (citrates) and inorganic acids produced from industrial wastes. A further innovation is the development of water remediation with Li recovery from all wastewater streams generated, through the implementation of polymeric nanocomposite membrane separation with direct Li recycling for Li in water concentrations down to 0.6mg/L. The recycled parts will be assessed for (closed-loop) battery and other secondary applications for precursors and semi-products by industrial partners Verkor and Hydro, through reformulation and upcycling of battery materials and validation of remanufactured batteries. An optimised process flow will be determined to achieve commercially viable recycling with maximised recovery rates and minimal environmental impact.

Battery technology emerges as a key solution for cutting carbon dioxide emissions across transportation, energy, and industrial sectors. Nonetheless, traditional research methods for developing new battery materials have typically depended on an Edisonian approach, characterised by trial and error, where each phase in the discovery value chain is sequentially reliant on the successful execution of preceding steps. Development and optimization of novel batteries is a process that spanned around a decade. To face this challenge, it is necessary to accelerate the discovery and optimization of next-generation batteries through the development of materials and interface acceleration platforms. The FULL-MAP project aims to revolutionize battery innovation by developing a materials acceleration platform that amplifies human capabilities and expedites the discovery of new materials and interfaces. This pivotal initiative focuses on automating laboratory operations and conducting fast, high-throughput experiments. It integrates AI and machine learning-accelerated multi-scale and multi-physics modeling, supporting intelligent decision-making. FULL-MAP's comprehensive, modular approach encompasses the inverse design of materials, autonomous orchestrated production via both traditional and novel synthesis routes, and extensive high-throughput characterization methods. These methods span ex-situ, in-situ, operando, on-line, and post-mortem analyses at various levels, from material to cell assembly and testing. It simulates the entire battery development process, from material design to battery testing, considering environmental and economic factors. By integrating computational and experimental methods with AI, Big Data, Autonomous Synthesis, and High-Throughput Testing, FULL-MAP aims to fast-track the development and deployment of next-generation materials and batteries, significantly advancing sustainable battery technology.

AID4SME will facilitate SMEs in developing combined AI and data solutions for large scale resource optimisation challenges for industries that have significant impact on the objectives of the Green Deal. Minimum 20 SMEs, selected through 2 open calls, will receive FSTP to develop these solutions with the support of a Community of Practice (COP). The ambition is to create a COP that will continue after the project lifetime. AID4SME brings together 9 technology blocks and low-TRL playgrounds from 4 scientific partners, to educate and support the SMEs. Additionally, 4 large industry partners (from automotive, whitegoods, battery and energy sector) provide real-life large scale resource optimization challenges that require combined AI and data solutions, and high-TRL playgrounds to integrate and demonstrate the solutions.AID4SME offers an open platform that is flexible to bring in challenges from outside the consortium. AID4SME provides the infrastructure and learning environment that enable the SMEs to solve the challenges, demonstrate solutions and grow into impactful enterprises. The technology blocks cover a wide area of AI & data technologies for the full cycle of data collection, creation of insights, decision support and automation. These technologies have the potential to have significant impact on the Green Transition and boost EU competitiveness for industries. AID4SME will collaborate with the AI-on-Demand platform to enrich its repository with the AID4SME tools and framework, while it is open to deploy the tools/frameworks already available on the AI-on-Demand platform for new use cases. AID4SME will assess the impact of the developed technologies on Green Deal objectives and on social and human aspects. AID4SME brings along partners who are experienced in re-skilling and up-skilling of SMEs and applying standardization as enabler for exploitation. The wide geographical coverage, with partners and DIHs from all across Europe, ensures maximum impact.