HARARE will demonstrate sustainable pathways to produce metals using hydrogen as an enabler, for removing waste and valorising materials in carbon free processes. The consortium’s concern and thus the drive to build this initiative, starts with an industry that is key contributor to a sustainable future: the metallurgical sector. The switch to renewable energies requires vast amounts of metals, such as steel and aluminium for solar panels and wind turbines, and copper for bolstering the electricity grid necessary for transport and industry. However, the metallurgical industry amounted to 70 million tons direct CO2 emitted in 2017. Moreover, carbon-based processes make the European metallurgical industry dependent on imports. Using hydrogen as a reductant to substitute carbon is one of the few ways metallurgical industry can potentially become truly free of CO2-emissions, utilizing raw materials that can be produced in Europe. HARARE’s vision is to tackle these challenges and become part of the solution, making the metallurgical industry more sustainable by presenting a circular concept that is based on a two-fold reasoning: 1) Recover wastes with hydrogen. choosing two representative wastes from the copper and aluminium production processes, namely: flash smelter slag from primary copper production and Bauxite residue (BR) from aluminium production. 2) Hydrogen-based processes will allow for an environmentally friendly metal industry while decreasing dependence from hard coal imports and being cost competitive. HARARE will thus eliminate waste from the metallurgical industry while recovering valuable materials, and increasing the use of hydrogen in the industry, thereby increasing its circularity, the utilization of raw materials and the profitability, lessening the negative side-effects on the community, and making steps toward the less carbon-dependent metallurgical industry necessary for a sustainable future.

The main vision of CABRISS project is to develop a circular economy mainly for the photovoltaic, but also for electronic and glass industry. It will consist in the implementation of: (i) recycling technologies to recover In, Ag and Si for the sustainable PV technology and other applications; (ii) a solar cell processing roadmap, which will use Si waste for the high throughput, cost-effective manufacturing of hybrid Si based solar cells and will demonstrate the possibility for the re-usability and recyclability at the end of life of key PV materials. The developed Si solar cells will have the specificity to have a low environmental impact by the implementation of low carbon footprint technologies and as a consequence, the technology will present a low energy payback (about 1 year). The originality of the project relates to the cross-sectorial approach associating together different sectors like the Powder Metallurgy (fabrication of Si powder based low cost substrate), the PV industry (innovative PV Cells) and the industry of recycling (hydrometallurgy and pyrometallurgy) with a common aim : make use of recycled waste materials (Si, In and Ag). CABRISS focuses mainly on a photovoltaic production value chain, thus demonstrating the cross-sectorial industrial symbiosis with closed-loop processes.

COBRA aims to develop a novel Co-free Li-ion battery technology that overcomes many of the current shortcomings faced by Electrical Vehicle (EV) batteries via the enhancement of each component in the battery system in a holistic manner. The project will result in a unique battery system that merges several sought after features, including superior energy density, low cost, increased cycles and reduced critical materials. To achieve these ambitious targets we will: upgrade the electrochemical performance by focusing on Co-free cathode, advanced Si composite as anode and electrolyte/separator; cell manufacturing and testing for electrical and electrochemical performance; leverage the use of smart sensors and advanced communication to optimise the system control; battery-pack manufacturing that deliver cost-effective and environmentally sustainable battery over its lifetime. The proposed Li-ion battery technology will be demonstrated at TRL6 (battery pack) and validated it on an automotive EV testbed. The involvement of several leading organisation for battery manufacturing ensure easy adaptation to production lines and scale up to contribute to a higher market adoption while helping to strengthen Europe’s position in the field. Overall, the project includes the participation of 3 universities, 7 RTOs, 4 SMEs and 5 enterprises covering the entire value chain and strongly engaging EU battery industry.

ICARUS aims to demonstrate modular processing solutions at industrial scale to retrieve 95% of high-value raw materials from silicon ingot and wafer manufacturing, through eco-efficient processing, refining, and transformation of industrial silicon, graphite and silica waste streams. Industrial symbiosis will provide refined raw materials for further industrial high-end applications. Material closed-loop systems will enable a circular economy for silicon ingot and wafer manufacturers, potentially unlocking substantial volumes of raw materials: 9.600.000 t of silicon, 1.165.300 t of silica and 64.000 t of graphite by 2050. ICARUS will demonstrate: 3 innovative industrial pilots producing silicon, silica and graphite raw materials; 1 pilot converting silicon waste into full value industrial commodities: - Pretreated and purified silicon, silica and graphite raw materials (RESITEC), - Pyrometallurgical process using recylced silicon, silica and graphite for high purity silicon (NOSI), - Granular silicion feedstock for photovoltaic applications (ROSI), - Full value industrial commodities: green hydrogen, silica and silicates (LUX), for different high-end applications with strict raw material quality standards, to assess the technical and economic viability of these applications: - Si-photovoltaics (CEA) - Al-Si alloys (GRANGES) - Thermoelectric modules and generators (MMEX) - Lithium ion battery cells (CIDETEC, SGLBS) - Silicon carbide powders (FIVEN) - Fine-grained graphite (SGL) The R&D team consists of internationally recognised partners, SINTEF, CEA, INP, UCY and CIDETEC, that will support with services for more efficient implementation of innovations developed in the project. Technological feasibility will be assessed by the industry partners, while BIFA will carry out environmental assessment, CHEMCON will conduct economic and market viability assessment for the ICARUS value chain. AYMING will be in charge of dissemination and communication activities.