IbD® will create a holistic platform for facilitating process intensification in processes in which solids are an intrinsic part, the cornerstone of which will be an intensified-by-design® (IbD). The IbD approach is hinged on the use of robust data about a process to ‘redesign’, modify, adapt and alter that process in a continuous, intensified system, and will be the new paradigm in the intensification of processes based on statistical, analytical and risk management methodologies in the design, development and processing of high quality safe and tailored chemicals, pharmaceuticals, minerals, ceramics, etc. under intensified processes. The IbD Project will deliver the EU process industry with an affordable and comprehensive devices-and-processes design-platform endeavoured to facilitate process intensification (PI), which specially targets -but is not limited to- solid materials processing. Five PI industry case studies will be implemented in mining, ceramics, pharmaceutical, non-ferrous metals and chemical processes using the IbD approach and to validate the IbD methodologies, tools, PI modules, control and fouling remediation strategies and the ICT Platform itself for the industrial implementation of PI in processes involving solids. The Platform includes design modules for the commonest intensified reactors-Rotating fluidized beds, micro-structured reactor and spinning disk, among others, as well as a generic Module Builder -equipped with a set of both proprietary and third-parties design tools- for designs carried out on the basis of radically novel ideas. The IbD Platform output is basically a data set that comprises the intensified reactor design -ready to be built or assembled-, an optimised whole process design including the upstream/downstream intensified unit operations and their solids handling capability, as well as cleaning methods, etc. and the expected economic and environmental quantitative impacts.

The European Union has underexploited potential to produce critical raw materials (CRM) and special metals, as stated in the Study on the EU’s list of Critical Raw Materials (2020). Concretely, the battery sector is considered as a key strategic sector for the EU due to the increased use of batteries in different important sectors such as electric mobility. Thus, METALLICO proposal presents a new opportunity for the European Union. It is composed by an strategic consortium along the value chain, including mining and industrial sites with primary and secondary sources of critical and battery metals (Li, Co, Cu, Mn, Ni); experienced partners to pilot novel processes for producing battery-grade materials based on previous projects and activities; industrial and SME end-users in the battery, cement, paint, and ceramic sectors; and partners to demonstrate the social-license-to-operate (including the support of government bodies), sustainability and commercial chances that the solution represents. Worldwide, these battery metals are predominantly in Chile, Australia, South Africa, China, and The Democratic Republic of Congo, representing a high risk for the EU in terms of supply shortage. For example, in the case of Li, the EU import reliance is 87% for lithium concentrates and 100% for refined compounds as there is no domestic refining . METALLICO includes 4 cases studies in the EU to recover: battery-grade Li2CO3 from a primary spodumene/lepidolite/petalite deposit; Co concentrates and battery-grade CoSO4 from a mine secondary resource (CLC); and Cu, Co, Mn, and Ni concentrates from metallurgical slag from a Pb refining company (KHGM) and secondary mine tailings (THARSIS). Upscaling of sustainable and innovative upstream and downstream processes will demonstrate the techno-economic recovery and production of these critical and important metals for the EU.