ZEvRA's main objective is to improve the circularity of light-duty EVs throughout their entire value chain, from materials supply and manufacturing to end-of-life (EoL) processes, which aligns with the European Union's goal of achieving zero CO2e emissions by 2035, particularly in the EV value chain. To do so, ZEvRA will develop a Design for Circularity (DfC) methodology and a holistic circularity assessment aimed at improving the production of electric vehicles (EVs) based on the 9Rs. This methodology will be validated by developing zero emission solutions for the most important automotive materials, covering > 84% material mix: steel, three versions of aluminium (wrought, casting, and foam), thermoplastics composites (long and continuous fibre-reinforced), unfiled/short fibre plastics, glass, tyres and Rare Earth Elements (REE). These solutions will be supported by a set of digital tools to support the manufacturing of the use cases, the assessment of circularity, traceability, and the virtual integration of components into a full replicable vehicle. To maximise the outreach of our methodology and zero emission solutions, ZEvRA will develop a dedicated training & upskilling programme for the automotive workforce and academia, together with activities aimed at increasing awareness & acceptability of the proposed zero emission solutions. Lastly, circular business models targeting EoL and logistics aimed at improving the economic feasibility of circularity in EVs are advanced. ZEvRA’s innovations aim to improve zero emission approaches in the life cycle and value chain of at least 59% of European EVs by 2035 through the 5 OEMs and Tier 1’s that are part of the consortium, which includes industry and academia covering the entire automotive value chain.

The EC and national public officials are well aware of the economic importance and supply risk of Critical Raw Materials and are promoting solutions which are feasible, reliable and cost-effective to reduce this dependence. SALEMA addresses this concern for the CRM-reliant high performance Aluminium grades required in electrical vehicles. Changing the input materials required to produce these advanced alloys, SALEMA proposes a circular economy model using scrap metal as an alternative source of Critical Raw Materials and the substitution of CRM for commonly available alloying elements. These developments will be deployed in four industrial pilots (High Pressure Die Casting, Cold and Hot Sheet Stamping, and profile Extrusion), representing the most relevant processes in aluminium manufacture for lightweight automobiles. SALEMA puts together an industrially and user-driven consortium that represents the whole sector of aluminium in automotive applications, who will extensively work during 3 years to proof that the presentedmeasures are competitive, technically feasible and contribute towards circular economy strategies and sustainability goals. The project addresses in a coordinated and cooperative manner the key challenges in the different levels of the value chain: improving scrap classification and sorting systems to turn scrap into a valuable raw material; demonstrating the feasibility to substitute CRMs in alloying systems; developing recycled aluminium alloys with improved mechanical performance; optimizing High Pressure Die Casting, sheet metal Stamping and Extrusion processes in a timely and cost-efficient manner in order to ensure the adoption of the developed alloys. SALEMA will deliver 4 industrial pilots, validate the new developed Al alloys with 5 car-part demonstrations in 5 industrial case studies, which guarantees a prompt industrial deployment and take up.

Industrial symbiosis (IS) has gain great attention in the last years due to its high potential for energy and resources savings. However, there is still a need for enhancing the knowledge base for IS in Europe, especially in what regards to the implementation and operation phases, which must be supported by harmonised frameworks and data reporting structures that ensure data accuracy and comparability in existing and new IS initiatives. Under this framework, CORALIS has been designed as a demonstration project for the generation of real experiences on the deployment of IS solutions and the overcoming of the barriers faced by these initiatives. In order to properly address this complex issue, CORALIS will address three factors (technical, managerial and economical) that will set the basis for the definition of the IS readiness level, a useful indicator establishing the feasibility of the overall IS initiative. In addition to specific developments on each of these factors, CORALIS will provide a harmonised framework for the monitoring of results and evaluation of their impact from a life cycle perspective. This impact assessment methodology will be implemented into a virtual assessment platform that will support the operation of the involved industrial parks. The overall approach of CORALIS will be demonstrated in a total of 3 industrial parks, each of them supported by an IS facilitator, a neutral actor in charge of guiding the IS initiative and exploiting its full potential. Moreover, 3 additional industrial parks will follow the project results in order to replicate them by implementing additional IS initiatives after the project’s end. Further replication is expected by gathering the project results in CORALIS Handbook for supporting the implementation of IS, by providing recommendations on regulation and standardization and by establishing a continuous dialogue with main European stakeholders following an ambitious dissemination and exploitation strategy.