The increasing e-mobility will trigger a battery waste problem (9Mtons/year by 2040) despite that many of the used LIBs are suited for 2nd-life applications for an additional 10 years, representing an opportunity to diminish energy and raw materials dependencies in Europe. Technical hurdles are preventing the re-use and recycling of Li-ion batteries. Besides the heterogeneity of the battery stock, assessing their condition for further usage is a slow process performed with equipment not suited for industrial contexts while. Dismantling packs and modules is in addition a costly and slow manual process because its automation faces extremely complex, multi-scale, cluttered and densely packed environments. REBELION will validate two circular schemes (including Light e-vehicles) to maximise 2nd life utility and domestic applications, enabled by a disruptive fast battery testing based on Electronic Noise Analysis, and an autonomous pack and module disassembly system with re-configuring capabilities for the ongoing battery types and formats. Additionally, a novel labelling system supported with blockchain, digital battery passport and ecolabel technology will provide key information to dismantlers, recyclers, re-manufacturers and users. Processing large volumes of used batteries increases the risks of thermal runway incidents, requiring thus novel safety protocols and systems. REBELION will add thermal monitoring and the design of a smart container for storage and transportation with thermal and gas sensing layers to monitor the limiting oxygen index and lower explosive limits, and a cooling system that activates when thresholds are surpassed. REBELION consortium covers all the value chain, including advanced robotic line and car manufacturer, bringing key knowledge, proprietary technology, and pilot validation facilities. The combination of 4 research centres and 7 industrial partners will ensure technology transference from lab to industrial context.

The negative environmental impacts results from the linear ‘take, make, dispose’ and dominant economic models of our time, traditionally adopted by decision-making of main stakeholders around mobility are changing thank to EV's irruption, but Lithium-Ion Batteries (LIBs) are not yet green enough to reduce mobility footprint to lowest levels. Thus, recycling has to be developed to achieve higher efficiencies and recovery rates to reintroduce Critical Raw Materials from End-of-Life (EOL) LIBs. Recycling technology is still at the lab-scale due to the complex structure of EOL LIBs. Currently, pyro-metallurgy is the most applied method in the industry. Although this process does not need pre-treatment, its energy-wasting, the equipment investment is large and it will cause serious pollution. In response to these problems, many companies have developed hydrometallurgical processes, that can recover Li and Al with low energy consumption. However, it requires pre-treatment, leaching, purification and other steps, and it could be a long way. FREE4LIB aims to develop at TRL 5-6 technologies to achieve 6 new sustainable and efficient processes to recycle EOL LIBs (dismantling, pre-treatment and 4 materials recovery processes) delivering innovative recycling solutions to reach highly efficient materials recovery (metal oxides, metals and polymers) improving the supply of secondary resources at EU level. FREE4LIB also will deliver 3 processes aiming at metals and polymers re-using and electrode synthesis for re-manufacturing new LIBs, and it will study options to harness non-reusable elements. It will also deliver a Battery Passport (BP) methodology to improve processes traceability. Besides, 2 Open Platforms will be deployed: BP and Data-driven models for the process’s optimisation. At end, to validate and spread FREE4LIB: new LIBs will be assembled on battery packs and engagement activities with citizens, policymakers and battery stakeholder will be carried out, respectively.

This project aims to develop and implement a circular economy approach for sustainable products and services through their value and supply chains. Three new circular economy business models will be developed including (i) co-creation of products and services, (ii) sustainable consumption, and (iii) collaborative recycling and reuse. The Co-creation of Products/Services model will bring end-users closer to the design and manufacturing phases by identifying consumer preferences via Big-data online mining product reviews and evaluating product specifications and prototypes via Living Lab to customise the end-user requirements. Benefited from the co-creation features, sets of sustainable production methods will be implemented and new products/services will be created. The Sustainable Consumption model will develop a method to calculate the eco-points of products based on the outcome of FP7 myEcoCost project, assess product environment footprints (PEF), provide a traceability solution to monitor product’s sustainability along the value chain, and support end-users and stakeholders to actively implement the circular economy via awareness raising and knowledge sharing activities. The Collaborative Recycling/Reuse model will develop a system for stakeholders to interact with each other to facilitate the use/reuse of end-of-life products and reduce waste, and implement the eco-credits awarding scheme to encourage people to recycle/reuse. This project will be demonstrated at a large scale in electrical and electronic products and farming/agri-foods sectors, provide an effective means to communicate with wide communities to disseminate the project outcome, and involve a large number of stakeholders along value and supply chains throughout the project lifetime, including end-users, producers, researchers and civil society. An ICT platform will be developed to support the development, implementation, demonstration, communication and dissemination.

Circular TwAIn will lower the barriers for all the stakeholders in manufacturing and process industry circular value chains to adopt and fully leverage of trusted AI technologies, in ways that will enable end-to-end sustainability, i.e. from eco-friendly product design to the maximum exploitation of production waste across the circular chain. To this end, the project will research, develop, validate and exploit a novel AI platform for circular manufacturing value chains, which will support the development of interoperable circular twins for end-to-end sustainability. Circular TwAIn will unlock the innovation potential of a collaborative AI-based intelligence in production based on the use of cognitive digital twins. Moreover, based on the use of trustworthy AI techniques, Circular TwAIn will enable human centric sustainable manufacturing, fostering the transition towards Industry 5.0. Furthermore, Circular TwAIn will enable the integration and combination of different data from various sources over entire product life cycle considering sustainability aspects. The goal is to create and deliver innovative services among the members of the data ecosystem; these services will be embedded in AI-based Digital Twins, supporting an unambiguous communication when realizing complex services for sustainable manufacturing. The ambition of Circular TwAIn is to unleash the sustainability potential of AI technologies in circular manufacturing chains through: (i) Introducing AI optimizations in stages where AI is still not used (e.g., AI-based product design); (ii) Using AI for multi-stage and multi-objective circular optimizations that could improve sustainability performance. In this direction, the project will leverage information from a circular manufacturing dataspace that will provide access to the datasets needed for multi-stage and multi-objective optimizations.

BATRAW main objective is to develop and demonstrate two innovative pilot systems for sustainable recycling and end of life management of EV batteries, domestic batteries, and battery scraps contributing to the generation of secondary streams of strategically important CRMs and battery RMs. The first pilot will deliver innovative technologies and processes for dismantling of battery packs achieving recovery of 95% of battery pack components and separating waste streams including cells and modules by semi-automated processes for recycling. BATRAW's second pilot will scale and demonstrate efficient pre-treatment and continuous hydrometallurgical recycling of battery cells and modules including innovative steps for C-graphite, Al and Cu separation from black mass and Mn extraction, achieving a recovery of the full range of battery RMs (Co, Ni, Mn, Li, C-graphite, Al and Cu) at selectivity of 90-98%. Innovations wil be scaled and demonstrated in a pilot systems with recycling capacity of 1 ton lithium-ion battery (LIB) packs dismantled per shift (8 hours) and treat 300 kg BM per day. BATRAW outcomes are of strategic importance within the prospects of the exponentially growing EU battery market and reducing EU import dependency of CRMs. The project will further promote the overall sustainability and circularity of battery products and raw materials by developing new procedures for battery repair and reuse, enabling faster diagnostics and conversion of EV packs into second life batteries, delivering eco-design guidelines for battery manufacturing, demonstrating blockchain platform for raw material tracking and supply chain transparency (Battery Passport) and delivering guidelines for safe transports and handling of battery waste. The project aims to maximize market uptake and impact through ambitious C&D&E plan including circular business models, innovations workshops, dissemination in EU platforms, policy briefs and other strategies to reach markets and stakeholders.