The answer to the current Raw Material supply challenge faced today in Europe, lies in technological innovations that increase the efficiency of resource utilization and allow the exploitation of yet untapped resources such as industrial waste streams and metallurgical by-products. One of the key industrial residues which is currently not or poorly valorised is Bauxite Residue (BR, more commonly known as “red mud”) from alumina refineries. Bauxite residue reuse solutions do exist as stand-alone but pooling them together in an integrated manner is the only way to render bauxite residue reuse viable from an economical point of view and acceptable for the industry The RemovAl project will combine, optimize and scale-up developed processing technologies for extracting base and critical metals from such industrial residues and valorising the remaining processing residues in the construction sector. In term of technological aspects, RemovAl will process several by-products from the aluminium sector and from other metallurgical sectors in Europe (SiO2 by-products, SPL, fly ash,and others). The different waste streams will be combined to allow for optimal and viable processing in different technological pilot nodes. The technologies and pilots in most cases have already been developed in previous or ongoing projects and through RemovAl they will be pooled together and utilized in a European industrial symbiosis network. In term of societal or non-technological aspects, RemovAl will gather key sectors like the non-ferrous metal and cement sectors in order to secure a true industrial symbiosis through a top-down approach considering also legislation and standardisation at European level in order to facilitate the implementation of the most promising technical solutions.

Recognizing the significance of energy efficiency in industry and carbon emissions reduction, FLEXHYON is proposing a clever combination of alternative fully electrified heating systems (microwave, heat pumps, ultrasound) to tackle three specific industrial processes: ultrafast drying of compact material, drying of granular materials and distillation/extraction of ground material to address their urgent need to transition from fossil energy to renewable and low-carbon energy sources. Three optimized prototypes will be built and demonstrated in 3 industrial environments: ceramics, feed production, biomass. The quality and economic impact of the developments will be evaluated using LCA and LCC; environmental and technical performances, health protection, safety will be demonstrated and validated. Sound market strategies will be developed, giving clear indications on scalability, transferability and replicability across different industrial sectors, commercialization and deployment will be achieved through development and validation of set of business models for the 3 business cases. The FLEXHYON solutions will exhibit significantly higher energy efficiency in comparison to traditional fossil fuel-based heating technologies, therefore leading to a reduction in GHG emissions, maximizing primary energy savings, and enabling higher production flexibility (e.g. production on-demand, production on-site). Their scalability (upscaling, downscaling) will allow to better follow market demand and enable leaner production paradigms. To achieve the project goals, FLEXHYON combines 9 partners covering the whole technical value chain required for the development and validation of alternative fully electrified heating systems. The Consortium will also implement different dissemination and communication activities to raise awareness about the benefits of alternative heating systems in industry and exploitation opportunities from know-how generated and exploitable results developed.

PEACOC will showcase a first-of-a-kind economically and environmentally viable pre-commercial metallurgical system for recovering Precious Metals (PMs) (i.e. Platinum Group Metals (PGMs) identified as critical raw materials by the European Commission (EC), as well as gold (Au) and silver (Ag)), highly important for the EU economy, from a wide variety of abundant end-of-life (EPEACOC will showcase a first-of-a-kind economically and environmentally viable pre-commercial metallurgical system for recovering Precious Metals (PMs) (i.e. Platinum Group Metals (PGMs) identified as critical raw materials by the European Commission (EC), as well as gold (Au) and silver (Ag)), highly important for the EU economy, from a wide variety of abundant end-of-life (EoL) products in Europe. The concept is mainly based on previously developed recovery and refining technologies to TRL 5 in the PLATIRUS Research and Innovation project (Micro-Wave assisted leaching and Gas Diffusion Electrocrystallization GDEx), which were flagged by the Innovation Radar initiative of the EC as excellent innovations and showed a significant cost reduction and lower environmental impact compared to state-of-the-art hydrometallurgical processes as will be shown throughout the proposal. The PEACOC system will be demonstrated at pre-commercial scale at TRL7 with capacity to treat ~50t of PMs concentrates/year i.e., with a recovery capacity of i)2 kg PGMs/week from spent autocatalysts (containing ~2.5kg PGMs/t), ii) 0.5-1 kg Au/week from Printed Circuit Board Assembly (PCBA) with a focus on low and medium grade PCBA (containing 20-100 g Au/t) that are currently poorly valorized in industrial smelting processes due to low PM concentrations, and iii) 10 kg Ag/week from EoL Photovoltaic (PV) panels (containing ~3-10 kg Ag/t) which will be an abundant resource in Europe in the coming few years. The project will demonstrate the production of PMs at a profit margin up to 80% with respect to current PMs market prices.