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.

BatteReverse aims to enable the next generation of battery reverse logistics (RL). It will develop a more efficient and universal method for battery discharge and first diagnosis for a wide range of Li-ion battery types, safety packaging with a monitoring system reducing thermal runaway risk during transportation of batteries, automated dismantling and sorting of battery components based on a safe and more efficient human-robot collaboration, and a more precise and faster Remaining Useful Life assessment of battery modules for 2nd life applications based on acoustic testing and machine learning algorithms. On top of that, BatteReverse will develop a Battery Data Space with standardised labelling and battery passport functionalities to improve battery identification. We will connect the stakeholders through a community platform and analyse the entire RL process by a digital twin (DT) simulation that will optimise profitability of RL circular business models. The innovations will be integrated and demonstrated in an operational environment in two use-cases for end-of-first-life (EoFL) EV batteries - recycling and repurposing – mirrored with the DT simulation. By 2026 we expect these developments to contribute to following outcomes: increase recycling efficiency by 5%, raise share of repurposed EoFL batteries to 10%, reduce risk of severe events in reverse logistics to 1/10.000, successfully simulate two successful RL business models and to have a stakeholder’s community platform with 50+ stakeholders. These outcomes will contribute to the sovereignty of the EU in the battery sector. By further uptake of the developed results beyond the project, BatteReverse targets to avoid the use of 3.691 tonnes/year of primary critical raw materials, on top of that avoid the deployment of 100,8 MWh capacity of new batteries yearly while capturing an extra €30,24 million/year value out of EoFL batteries and avoiding 31 severe risk events/year within the EU RL battery chain by 2029.