Project duration: 01 March 2018 – 30 November 2019

Objective

Rare earth elements (REE) are essential for the transition towards sustainability. However, REE are critical metals and only one country, China, dominates the entire supply chain with its own domestic pitfalls such as environmental pollution, illegal mining, impacting the international market.

As highlighted by the European Rare Earths Competency Network, boosting supply security through enhanced cooperation among European end-users and other stakeholders should receive top priority. However, enhancing collaboration between the REE supply chain is a major challenge because unlike many other types of metals and elements, there is no REE industry association who gathers stakeholders together. The reason an association like this does not exist is not that it is not needed. On the contrary, the REE industry faces numerous obstacles such as inefficient recovery of REE from end users/end products, the high environmental impact from production and processing, high volatility of the raw material prices and low competition from countries outside China. To combat these issues, GloREIA, concurrently gathers key supply chain actors currently already on the global market and share and create information which leads to an innovative REE industry of the future.

The solution (technology)

GloREIA contributes to a novel, circular business models across REE value chains. The project will also set up and manage a database of life cycle inventories with and for industry members and scientists in the REE field.

Its challenges include the development of a strong REE network that includes China, providing a space for research activities to be launched in industry, and strengthening the capacity to influence REE supply on a global scale.

Partnership

• Katholieke Universiteit te Leuven (KU Leuven), Belgium (Lead partner)
• Geological Survey of Denmark and Greenland (GEUS), Denmark
• Kolektor Magnet Technology GmbH, Germany
• Leiden University, Netherlands
• Magneti Ljubljana d.d., Slovenia
• Neo Performance Materials, Estonia

For more information, please visit the official website of the project.

Project duration: 1 May 2016 – 30 April 2019

Objective

Reducing the need for landfill deposits by turning waste streams from the metal industry into valuable products. Waste streams targeted originate from

The solution (technology)

Waste streams targeted originate fro carbothermic production of silicon & ferro-manganese alloys and from metal and carbon containing waste streams from steel and metal recycling activities. The demonstration will be done in a value chain at demonstration scale able to achieve ~ 15 tons of FeMn alloys.

Partnership

• ERAMET Research, France (Lead Partner)
• ArcelorMittal Maizières Research SA, Belgium
• Centre de Recherches Métallurgiques asbl (CRM Group), France
• Comet Traitements SA, France
• EUROTAB SA, France

Project duration: 1 January 2019 – 31 December 2020

Objective

The tendency of the automotive sector towards solutions that minimise the emission of pollutant gases (CO2, NOx and particles) into the atmosphere, either because of the increasing social awareness to environmental conservation or because of new emission control regulations (Real Driving Emissions and Euro 6), has favoured the boom of Hybrid Electric Vehicles (HEV) and Electric Vehicles (EV) during the last years. As the vibro-acoustic behaviour of vehicles represents one of the main sources of discomfort, fatigue and even injury to passengers, it is a clear end-user purchasing decision factor. In line with this, it can be stated that lightweight trends are pushing car manufacturers to overcome new challenges in terms of noise, vibrations and harshness (NVH).

The solution (technology)

GREENNVH is proposing to develop 3 anti-vibration components for suspension systems with enhanced Noise, Vibration and Harshness performance, for HEV and EV, based on recyclable TPU solutions. Main benefits will be achieving CRM-free (natural rubber) components for the automotive market, improving NVH behaviour in suspension systems of TPU components, reducing anti-vibration components weight by 10%, and heading for recyclable raw materials like TPUs substituting those non-recyclable ones like rubber.

Partnership

• CIKAUTXO S. COOP., Spain (Lead Partner)
• BASF SE, Germany
• Katholieke Universiteit te Leuven (KU Leuven), Belgium
• LEARTIKER SCOOP., Spain
• NISSAN Motor Manufacturing (UK) Ltd., United Kingdom

Project duration: 1 January 2019 – 30 June 2021

Objective

The GREENY project focuses on increasing the energy efficiency of comminution and enabling the beneficiation of difficult to process secondary raw materials.  The raw slag, containing less than cost beneficially required of extractable metals, is to be used as a separate product for construction materials after comminution. During the project, emphasis is placed on improving and upscaling suitable crushing and grinding technologies for slag material to enhance the energy efficiency and performance of crushing equipment in demanding operational conditions. The processes are developed in general with difficult to refine secondary raw materials in mind, for example, materials which contain both brittle and ductile phases.

The solution (technology)

These objectives are met by upscaling new crushing and grinding processes and applying them to presently unused sources of secondary raw materials. As a use case, the GREENY project takes on the efficient reuse of the steel industry’s slag that is a side product in steel making. The design and optimization methodologies, processes and equipment that are developed are applicable also to other slags and secondary raw materials. In the GREENY use case, the slag contains valuable metals that can be extracted by a combination of selective comminution and metal liberation from the slag.

Partnership

• Metso Minerals Oy, Finland (Lead Partner)
• ERAMET IDeas, France
• Luleå University of Technology (LTU), Sweden
• Technische Universität Bergakademie Freiberg (TUBAF), Germany
• Teknologian tutkimuskeskus VTT (Technical Research Centre of Finland Ltd. VTT), Finland

Project duration: 1 January 2018 – 31 March 2020

Objective

Sales of electric vehicles (EV) show a clear upward trend in the coming years, where the EV market share is expected to grow from the current value of 3% up to 50% in 2050.

However, the new powertrain elements of the electric-powered vehicles (in particular battery, electric engine and power electronic systems) require working under certain conditions that are seriously influenced by extreme temperatures (cold and heat) and largely influence the efficiency performance of such elements, even being able to damage or directly disable the entire vehicle.

Such elements require a cooling circuit, responsible for keeping their components within a very narrow temperature window to optimize the electric vehicle autonomy and decrease energy losses. To do so, the cooling circuit materials must comply with the following requirements:

• Excellent insulation properties, in order to keep accurate temperature range.
• Maximum lightness, in order not to penalize EV autonomy.

The solution (technology)

Rubber, which is a non-recyclable and critical raw material (CRM) and is currently used in the cooling circuits, can no longer fulfil these demanding specifications. Therefore, OEM suppliers like CIKAUTXO, which provide ducts and components for water cooling circuits to the main vehicle manufacturers (such as VW, GM, FORD, RENAULT-NISSAN, DAIMLER, BMW or FIAT), are therefore facing a new business opportunity to develop structures made of new materials replacing natural rubber which comply with the new EV cooling demands.

GRIMEV project will, therefore, develop a new two-layer structured lightweight and recyclable material with improved thermal insulation for the cooling circuits of electric powered vehicles. The new material will be based on TPV (thermoplastic vulcanizates) and will lead to considerable environmental benefits like recyclability and, even more relevant, to the technical and economic feasibility of electric vehicles.

The final aim of the project is to start large-scale commercialization of the new cooling circuits one year after the end of the project. To do so, GRIMEV will first define the requirements of advanced EV cooling systems, develop the material, develop the manufacturing process of the cooling ducts, and finally manufacture a set of conduction prototypes that will be thoroughly modeled and tested both at a lab and real vehicle scale.

Partnership

• CIKAUTXO S. COOP., Spain (Lead partner)
• Centro Ricerche Fiat S.C.p.A. (CRF – C.R.F.), Italy
• French Alternative Energies and Atomic Energy Commission (CEA), France
• Deutsches Institut für Kautschuktechnologie e.V., Germany
• Katholieke Universiteit te Leuven (KU Leuven), Belgium
• MONDRAGON GOI ESKOLA POLITEKNIKOA S. COOP. (MGEP), Spain

Project duration: 1 January 2018 – 31 March 2021

Objective

Wear is understood as a loss of material and consequently of part geometry due to the interaction of the working part with external bodies, as particles or other moving parts in the machinery. Part failure by wear is one the most relevant sources for part malfunction in the industry. Apart from the cost of part reparation or substitution, wear failure in large industrial parts has an important economic impact on production efficiency because of production losses during machinery downtime.

Wear prediction in a quantitative manner is not possible nowadays. Fracture prevention in many structural parts in bridges, airplane, vehicle, etc, is routinely carried out and it is considered as state of the art. However, wear is difficult to predict because it implies complex interactions between bodies, and acting forces are not easy to measure or predict. In this sense, the possibility of having a software to predict, localize and quantify wear would be very helpful to define maintenance and reparation task of large industrial parts, as those working in the mining industry.

Parts in mining industry machinery are usually subjected to harsh working conditions, with high forces, abrasive media, low temperature and big impacts. All these conditions give rise to severe wear damage in many parts of the machinery, with the associated high costs for maintenance and substitution.

The solution (technology)

The project HARSHWORK addresses this topic by developing a software model to predict wear in parts working under harsh conditions. Likewise, the wear prediction model could be applied to other sectors, such as processing and recycling plants or hard materials design, providing operational savings to a wider number of companies and increasing the available market for the software end product.

This will optimize exploitation costs by reducing maintenance periods, decreasing costs and increasing performance of machinery. Project results are of keen interest to mining companies and mining equipment manufacturers, as well as a wider range of steelmakers, engineering, and recycling sector.

Partnership

• Luleå University of Technology (LTU), Sweden (Lead partner)
• Bianna Recycling SL, Spain
• Boliden Mineral AB, Sweden
• General Council of the Catalan Chambers of Commerce, Spain
• Fundació CTM Centre Technologic, Spain
• IDP lngenieria y Arquitectura Iberia, S.L.U., Spain
• LTU Business AB, Sweden
• Outotec (Finland) Oy, Finland
• Outotec Pty. Ltd., Australia
• SSAB AB, Sweden

Project duration: 1 January 2018 – 30 September 2020

Objective

Aluminium is used in aerospace to decrease the weight of planes in order to consume less kerosene. The mechanical strength of pure aluminium is not very high (e.g. aluminium foils). This can be improved by the introduction of nanoparticles inside the Al matrix, resulting in a much stronger alloy.

In addition, the project aims at using fine industrial aluminium residues in a short recycling loop to use it as raw material. A unique partnership is implemented involving raw material suppliers (Nanomakers, Mecachrome), 3D printer manufacturer (Renishaw), aerospace intermediates and end users (Zodiac and Mecachrome) and expertise of academics (KU Leuven, CEA).

The solution (technology)

Dispersing the nanoparticles homogenously in the Al matrix is difficult. This can however be achieved by mixing nano silicon carbide and aluminium powder. This powder is a very good starting material for 3D printers. Printers can manufacture 3D pieces than can be used for aerospace.

The project will demonstrate the upscaling of an advanced nano and metallurgical process, comprising both aluminium nanocomposite powder production and its conversion to a redesigned airplane seat component using additive manufacturing technology and recycled aluminium.

Partnership

• Nanomakers, France (Lead partner)
• French Alternative Energies and Atomic Energy Commission (CEA), France
• Katholieke Universiteit te Leuven (KU Leuven), Belgium
• Mecachrome, France
• Renishaw, United Kingdom
• Zodiac Aerospace, France

For more information, please visit the project website.

Project duration: 1 January 2021  – 31 December 2023

Objective

Li-ion batteries are a key technology for e-mobility. To supply the rapidly growing battery industry with sustainable and high-quality carbon additives, the low carbon footprint Acetylene Black of Orion and the resource-efficient Carbon Nanotubes of Arkema will be upscaled, combined and commercialised. The materials will be evaluated on lab and pilot scale by the Fraunhofer, Aalto and Customcells. An LCA will be performed by University Bordeaux.

The solution (technology)

Lithium-ion batteries are a key technology for the trendsetting European industries such as electric vehicles, portable electronic devices or a wide range of other applications where renewable energy is stored and supplied. The wide spectrum of applications opens a large market for the battery cells but also sets challenging requirements related to their energy/power density and cycle life. To reach these requirements, stable and high-performance carbons must be used as conductive additives.

Orion Engineered Carbons S.A. is the only European company that provides the newest technology to develop and manufacture high purity Acetylene Black (AB) conductive additives for lithium-ion batteries. Acetylene Black aggregates form a three-dimensional network to lower the internal resistance of battery electrodes and cells by enhancing the electronic conductivity. This material ensures that charge and discharge processes are performed effectively and Ohmic losses are minimised. Its high intrinsic electronic conductivity and purity, as compared to other Carbon blacks, leads to significantly higher power densities and longer battery cycle life.

Arkema, a strategic European material producer, is the only producer worldwide to produce carbon nanotubes (CNTs) from bio-based feedstocks in a 400 ton capacity pilot plant in Mont – Nouvelle Aquitaine Region – France. The resulting multi-wall purified nanotubes with a diameter between 12 and 15 nm, provided either as dry pellets or as liquid dispersions to improve the safety issues generally associated with CNTs, are tailored to customer-specific requirements in terms of metal impurities. The CNTs are compacted and purified downstream with a minimum of handling. This aspect is particularly important, since it allows the specific gravity to be increased by a factor of almost 3, which mitigates powdering, handling complexity and safety issues, and decreases the purification and transportation costs. Furthermore, this step dramatically improves the dispersion of the CNTs in solvents, as is desired by many customers.

In the HiQ-Carb project, the important step of “wet-beading” the AB will be scaled-up, resulting in a market-ready high-purity Acetylene Black Beads (AB BDS) to meet rapidly expanding market demands. Arkema will upscale the improved thinner CNTs having a diameter of 8-9 nm and already manufactured at a pilot scale. Together, Arkema and Orion will combine these two conductive additives in the form of a Carbon Mix dispersion. European lithium-ion battery manufacturers require a reliable, high volume supply of all critical raw materials from an EU-local source. This emerging industry will benefit from Orion’s Acetylene Black production at its site in France, from the fact that AB is produced almost without emission of CO2 and is non-toxic and from Arkema’s CNTs produced from a renewable bio-based feedstock.

The planned project consortium includes the leading materials producers Orion and Arkema as well as the cell producer Customcells. Application-oriented R&D, education competences and a Life Cycle Assessment are provided by the RTO Fraunhofer ISC, Aalto University and the University of Bordeaux. In total, three CLCs, three European countries and all edges of the EIT RawMaterials knowledge triangle will contribute to the HiQ-Carb Project.

Partnership

• Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. (Fraunhofer), Germany (Lead Partner)
• Aalto University, Finland
• Arkema France, France
• Custom Cells Itzehoe GmbH (CCI), Germany
• Institut Polytechnique de Bordeaux, France
• Orion Engineered Carbons GmbH, Germany
• Université de Bordeaux, France

Project duration: 1 January 2019 – 30 June 2022

Objective

To achieve society acceptance and profitability, the mining operations of the future have to be optimized in terms of impact on society and environment, safe and healthy working conditions and mining processes.
Mine digitalization (Mining 4.0) is identified as a key technology for success, while Mixed Reality (MR) is the most promising way to enable users to leverage all benefits to improve operational efficiencies, by integration of real world and virtual world in one 3D/4D environment.

The solution (technology)

By use of already existing MR hardware the development of specific solutions for selected underground mining issues, including an overall enterprise data infrastructure, is planned within HoloMine. The pilot solutions will evidence that mixed reality solutions are perfect for enabling rapid shaft and roadway inspection, machine maintenance, 3D model visualization, and quick decision-making. The mine environment will become an entirely new canvas to understand, investigate, learn, communicate and interact with.

Partnership

• DMT GmbH & Co. KG, Germany (Lead Partner)
• Deutsches Zentrum für Luft- und Raumfahrt e.V. (German Aerospace Center – DLR), Germany
• LTU Business AB, Sweden
• Montanuniversität Leoben, Austria
• Robotic Eyes GmbH, Austria
• Sandvik Mining and Construction GmbH, Austria
• Technische Hochschule Nürnberg Georg Simon Ohm, Germany
• Technische Universitaet Graz (Graz University of Technology), Austria
• Technische Universität Bergakademie Freiberg (TUBAF), Germany