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.

RECIRCULATE addresses the needs of European recycling sector by overcoming current challenges relating to automated dismantling and sorting; safe logistics; fast, cost-effective and reliable State of Health and State of Safety characterization. Combining these advances with a blockchain-based platform, that will combine the data collected during dismantling and recycling and the battery provenance, will enable a unique battery passport and virtual marketplace for e-mobility, consumer and stationary Battery Energy Storage Systems. This approach will enable the RECIRCULATE consortium to create a cascade approach that will enable increased end-of-life battery repair, reuse, remanufacture and recycling. The advances in RECIRCULATE will based on best-in-world innovations, including: • Automated dismantling based on Artificial Intelligence with accurate sorting by SoX and battery provenance for recycling. • Fast, cost-effective, reliable SoX characterization; Safe storage and transportation based on smart logistics solutions. • Blockchain-based Battery Passports that tracks key battery data, and enables both a complete circular system for e-mobility batteries and a unique, blockchain-based virtual marketplace. The unique virtual marketplace will allow for the creation of new circular business models for repair, reuse, remanufacture and recycling of second-life batteries, minimizing cost, time, energy and environmental impact whilst maximizing battery value. RECIRCULATE represents a pan-European consortium of world leading organisations that are looking to commercialize these technologies of European origin. The coordinator, Centria, is leading activities in battery dismantling. The consortium is strengthened by very large organisations, including: Ford, who are currently undertaking development for e-mobility, and DHL a global leader in logistics and reverse logistics as well as European SMEs with world leading technologies.

REVOLUTION focusses on overcoming the challenges hindering the use of recycled materials, but more broadly, restricting the widespread adoption of circular economy principles in the automotive industry. Forthcoming ELV directives are expected to recognise the potential for plastics to enable a circular flow of materials in the automotive sector. Implementing minimum post-consumer recyclate (PCR) targets in any new plastic components in vehicles are currently being discussed. These targets will disrupt the automotive industry. Currently PCR (closed-loop recycling) forms ~2% of the total plastics demanded across the automotive sector, and are not used in high-value or high-performing areas. REVOLUTION is proposing a disruptive innovation that will bring open-loop recycling to the forefront of automotive injection moulding. The variability of PCR causes a big problem for an industry where failure rates on 1 per million are accepted. REVOLUTION will use machine learning and artificial intelligence to optimise the input of recycled materials and injection moulding process to deliver high-quality parts. The AI-Platform will use data from three areas of the production process to predict part quality when using recycled materials. REVOLUTION will develop this platform, and develop a range of recycled formulations, including self-reinforced materials to deliver innovative components that offer light weighing, superior performance and distinctive end of life advantages for future EVs. REVOLUTION brings together leading organisations from European strong-hold industries such as automotive, chemicals and plastics. The automotive industry is represented by Fiat Chrysler Automobiles through Tofas, CRF and Tier 1s Farplas and MAIER. LyondellBasell, Clariant and Altuglas provide strong representation of the European excellence in plastics and chemicals. These are joined by leading research organisations and SMEs to bring a solution to market that addresses the entire value chain.