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EIT RawMaterialsSubstitution project portfolio
Julien Frey, Roland Gauß
November l 2018
EIT RawMaterials. A pan-European partner network
• Worlds largest community in the raw and advanced materials sector
• 122 Core and Associate partners
• 140+ Project partners
• 23 countries
• Headquarter in Berlin, Germany
What for Europe?
Develop raw materials and advanced materials into a major strength
1. Secure raw materials supply
2. Design sustainable products and services
3. Promote zero-waste, recycling, eco-design
SUBSTITUTION
EIT RawMaterials - Toolset
Intelligent Mine
Future Mobility
Circular Society
Substitution at several levels
Element
Material
Process
System
Images: Lewis – Jimenez-Villacorta 2013; Gauß et al. 2015; http://eresources.gitam.edu; Siemens
Rare Earth Balance Magnets based on (Ce,La,Nd)2Fe14B
for less critical magnets with medium performance
characteristics
Microstructure optimisation for enhanced performance:
grain size, gradient materials
Near-net-shape processing: green body pressing, 3D
printing, injection moulding
Optimized machine design for optimized use of material
Example of Nd-Fe-B in Wind Turbines
PGMPGM
Substitution is a disruptive intervention into an industrial ecosystem that comes with potentials and risks
• The by-product issue – the need for a cross-value chain perspective
• Substitutes are a threat to existing business
• A mass production of new materials and technologies may come with high costs for implementing new industrial production lines and infrastructure
• Hard to convince established industries to use a substitute – “never change a running system”
Image: after Hagelüken andMeskers, 2010; Reller 2012
EIT Raw Materials Substitution – Project portfolio
Master Education
(D3.2)
Network of Infrastructure (D4.1)
PhD Educatio…
Up-scaling projects (D4.2)
3
12
1
14
Master
NoI
PhD
Up-Scaling
78%
7.3%
10%
4.4%
Number of projects in 2018: 30Total Funding to be spent in 2018:
10.7 Million EUR
EIT Raw Materials Substitution – Project portfolio
Projects led by CLC in 2018 (30 projects)
CLC Baltic Sea
CLC Central
CLC South
CLC West
Industry
RTO
University
Funding split by Activity Field (10.7 Million EUR)
5
11
13
1
29%
36%
34%
15 Up-scaling projects
Battery Materials
3 Data Modelling
1
Electronics1Hard
Materials3
Lightweight7
Battery Materials
26 %
Data Modelling
4 %Electronics18 %
Hard Materials
15 %
Lightweight37 %
Total consolidated funding until 2018: 22,2 Million EUR
EIT Raw Materials Substitution – Up-Scaling project portfolio
Lighthouse Sustainable Materials for Future Mobility
Lead innovation across
Specific Value Chains
Materials for electrificationBatteries. Fuel cells. Magnets. e-Drives
Materials for lightweight designSteels. Non-ferrous alloys. Composites. Multimaterials.
VISIONSustainable and
cost efficient materials and
technologies for Future Mobility
---New solutions,
new business, well-trained people
Lightweightingand Design
New high strength steels
Increased use of fibre reinforced polymers in cars
Increased use of Al-Mg alloys in cars*
Electrification
Use of recycled carbon fibres Cost efficient production of thermoplastics in cars
Printed electronics
New coatings *
End-user markets
mining machinery, automotive,
aerospace, bikes
Short term Long term
Li ion batteries with increasing energy densities and lower Co contents
E-drives with higher torque density
Ce-/La substituted Nd-Fe-B permanent magnets
Fuel cells with low Pt content
Energy harvesting
Integration of photovoltaic cells in car body
Commercial post Li ion batteries: Li metal, Li-S, Na-ion
Recycled Nd-Fe-B permanent magnets
Additive Manufacturing of Nd-Fe-B permanent magnets
New high performance permanent magnet alloy
Fuel cells without Pt
Communication & autonomous
drivingOLEDS
New e-drive designs based on near net-shaped magnets
Magnetic cooling
CRM free displays and electronics*
Cell manufacturing in Europe
Austempered Ductile Iron*
Dedicated recycling of electronics
Self healing surfaces
Functionalized surfaces
Additive Manufacturing
Durability of electronics
Wear resistance & friction
Materials Data SpaceRUL – Remaining Useful Life
Lightweight packaging of batteries
Sustainable Materials Supply
and use
Definition of a CRM footprint per km
Recyclability
Production of strategic amounts of CRM in Europe: REE, Co, W, Sn, Au, PGM, In, Li
Safety
Increase production of strategic raw materials in Europe: Cu, Fe, Zn, Al
Corporate Social Responsibility
Alternative fuels
Collaborative mining projects with resource rich developing countries
Corrosion resistant materials for the use of synthetic fuels
Efficient production of synthetic fuels
Transversal actions
Thermoplastics for nat. rubber in car tube systems
Exploration and mining for critic. + strat. metals: Co, REE, Li, Cu etc.
EOL management of cars in a circular economy
Non-use of conflict metals
Cost effectiveness
Education at all levels
Standardization
Certification
Design rules
Modelling of materials and processes
Materials Data SpaceRUL – Remaining Useful Life
Safety training & emergency training
Improve reverse logistics
New dismantling technologies
Short term Long term
VISIONSustainable and
cost efficient materials and
technologies for Future Mobility
---New solutions,
new business, well-trained people
End-user markets
mining machinery, automotive,
aerospace, bikes
Workshop series on materials for mobility
Raw materials are key enablers for sustainable mobility
Mobility – Essential for society
Mobility – Key EU industrial for society
Mobility – Is changing
Mobility requires Sustainable Raw Materials
-> Sourcing of raw materials
-> Efficient recycling schemes
Its transformation is enabled by Advanced Materials
-> Innovation in substitution and new materials
Bosch
SolarImpulse
Value Chain Approach
EBA@250Industry Stakeholder Process
- Stakeholder consultation- Road mapping of actions- Collaboration, alliances- Investment
European CommissionGR Grow, GD RTD, DG Connect
- Member States consultation- SET Plan, Battery Action Plan- FET Flagship calls- H2020 calls
source: European Commission
EIT RawMaterials is active in implementing Actions from both work streams
The European Battery Alliance
Raw materials for batteries
LIBatteryRaw Materials
Nickel, Lithium, Cobalt, Manganese, Alumina and Graphite
Cathode
LCO -LiCoO2 (Tablets, Smartphones)
NCA-Li[NiCoAl]O
(Tesla S)
Berlin 06-2017 page6© DORFNER Analysenzentrum und Anlagenplanungsgesellschaft mbH
Source: AvicoenneEnergy 2017
NCA-Li[Nix Coy Alz ]O2 (Tesla S)
NMC -Li[Nix Mny Coz ]O2 (BMW,
Mitsubishi, Toyota, Honda …)
LMO -LiMn2 O4 (z.B. BMW, Nissan)
LFP -LiFePO4 (e-buses, industrial)
Anode
Graphite-spherical/naturaland synthetic
Separator
High Purity Alumina(HPA)Source: Avicenne Energy (2017)
Cobalt, Graphite, Lithium, Nickel, Manganese, Alumina
Cathode
• LCO – LiCoO2 (tablets, smartphones)
• NCA – Li[NixCoyAlz]O2 (Tesla S)
• NMC – Li[NixMnyCoz]O2 (BMW, Honda, Toyota)
• LMO – LiMn2O4 (BMW, Nissan)
• LFP – LiFePO4 (e-buses, industrial)
Anode
• Graphite – spherical/natural and synthetic
• SiC-composite materials
• Lithium – thin lithium foils
Separator
• High purity Alumina (HPA)
Our Battery Value Chain
Industry Partners:
EIT RawMaterials
The Innovation Power House of Raw Materials and Advanced Materials
EIT RawMaterials. Portfolio of “Battery” Projects
Further Cross Value Chain ProjectsCERA – Certification of Raw Materials
SUPRIM – Sustainable Management of Primary Materials
InternationalisationELI – European Lithium Institute
IRTC – International Round-Table on Criticality
NewEcoUpscaling Projects
Committed budget: 27.2 M€
LiRef. Multi-feed lithium technology
Challenge: Feeding refining process from various lithium sources
Solution: Electrochemical production of LiOH from spodumene concentrate
Key results: Sampling and testing model based on geological pre-conditions
Validation of multi-feed process for the production of LiOH
CAPEX and OPEX estimation of inter-country flow of material and value
Impact: Secure refining of lithium in Europe by 2023
Budget: 4.1 M€ Lead partner:
Duration: 2019 - 2021 Supporting partners:
ALIM. Advanced lithium-metal electrodes
Challenge: Substitute graphite with abundant and more efficient materials
Solution: Development of rolling mills for the production of ultra-thin lithium electrodes
Key results: Commercialization of lab-scale rolling mill for R&D purpose
Commercialization of rolling mill for large-scale production
Validation of lithium foils in battery applications (LFP and Li/S)
Impact: Promote solid-state batteries with high-energy density anode
Budget: 1.8 M€ Lead partner:
Duration: 2018 - 2020 Supporting partners:
AutoBatRec2020. Automotive battery recycling
Challenge: Automate or semi-automate disassembly of battery packs
Solution: Develop most economical model for collection, transport and re-use/recycling
Key results: Analysis of battery flow, collection and transport concepts
Techno-economic analysis of re-use versus recycling schemes
Validation of electrohydraulic fragmentation and sorting process
Impact: Propose solution(s) to large-scale recycling of automotive batteries
Budget: 3.0 M€ Lead partner:
Duration: 2018 - 2020 Supporting partners:
What is next in the Lighthouse Mobility?
Replicate the work done for the battery sector across other value chains:
• Magnet and e-drives
Secure independence from China for Rare Earth supply. Restore industrial manufacturing of magnets in Europe
-> Nascent value chain already present in KIC
-> Specific workshops and stakeholders consultation (2019 and beyond)
What is next in the Lighthouse Mobility?
• Lightweight design
Support EU Commission in decarbonating mobility. Provide the sector with the materials needed for autonomous, connected vehicles
-> Enhance value chain perspective (structuring work)
-> Attract in the KIC Tier 1 suppliers of the automotive sector
-> Gather stakeholders with battery and e-drive communities
… Coming Expert Forum 2019 !!!
RawMaterials is supported by the EIT,a body of the European Union
Dr. Julien Frey – [email protected]
Dr. Roland Gauß – [email protected]
Back Up Slides
Substitution – Unexploited potentials across all project categories
• Projects on toxicity and biocompatibility of new (nano)materials
• Rare Earth extraction and processing
• Materials Modelling and Big Data
• Fuel cells
• Graphene
EIT Raw Materials Substitution – Up-Scaling project portfolio
ALIM Advanced LI Metal electrodes. Mastering the production process of extra-thin lithium electrodes.
ECO COM'BAT Production of new composites for the next generation of Li ion batteries, the high-voltage batteries, based on green (less toxic, resource efficient and bio-based) and high-performance (high-voltage stable and highly conductive) substitutes for battery materials.
SIRIUS The goal of the SiRIUS project is to develop high capacity silicon – carbon composites anodes for lithium ion batteries based on carbon coated silicon nanoparticles
Virtual Upscaling Virtual Upscaling through Modelling Factory. A sequence of methods, tools and interface data models (ontologies) to find commonly defined practices for the upscaling process
SUPER-SMART Scale-Up of Printed Electronics Recyclable SMART materials. Direct printing on paper of sensors, displays and electronics. Use of organic materials instead of rare and toxic inorganic ones.
COFREE Co-free solutions for cemented carbides using Fe-Ni based alloys as substitute for Co-binders in cemented tungsten carbides; 1) production process of fine-grained, homogenous powders; 2) adaptation of quality control system
ECOPADS New brake pads for road vehicles featuring copper-free friction material, in order to eliminate the main source of copper released in urban areas
FASTRAM Upscaling of FAST sintering processes for the substitution of critical materials: W and Co; approach: up-scaling of specific electrical sintering process
EIT Raw Materials Substitution – Up-Scaling project portfolio
HIPERCO Advanced process comprising both Al and nanocomposite powder production and its conversion to
a redesigned airplane seat component using additive manufacturing technology and recycled Al
REVALUE REcycled carbon fibres for high VALUE composites. Process for recycled carbon fiber surface
modification and thermoplastic compound manufacturing
CaproKIC Upscaling of one step process for automotive continuous fiber Polyamide 6 composite parts based
on the in situ polymerization of e-caprolactam
SPAcE-MAN Sustainable Powders for AdditivE MANufacturing. New Fe-based powder alloys for Additive
Manufacturing with less critical elements (60 to 80% reduction for Cr, 100% for Ni!) and better
performance
GRIMEV New two-layer structured lightweight and recyclable material, based on TPV (thermoplastic
vulcanisates), with improved thermal insulation for the cooling circuits of electric powered vehicles.
RACE-TP Accelerating the development of acrylic based thermoplastic composite materials, a possible
substitute to metal based solutions
TAPA ThermoplAstic fluid handling Pipes for Automotive sector based on the substitution of a natural
rubber. New product (fluid handling pipes of vehicles turbo engines) and its manufacturing process
Mo
bili
ty
EIT Raw Materials Substitution – Networks of InfrastructureNoI LightBody Infrastructure and expertise network for Lightweight mobility : body and chassis Lightweight
RawMaterials4E-Energy
Raw Materials Solutions for E-Energy Technologies in the European Mobility Industry
Energy Technology
RAWMATS-4-POWERTRAIN
Raw Material solution for the European Powertrain Industry. Powertrain
MetLight Network of Infrastructure for Metal-based Lightweight Materials Lightweight
EXTREME Substitution of CRMs in components and coatings used under extreme conditions Surfaces and Coatings
FREECATS Critical raw materials-FREE CATalystS Catalysts
MagNet Magnetometry Network Magnetic Materials
MiRaCLE MIneral RAw materials replacement with nanoComposites by renewabLe Resources Exploitation
Nanocomposits
NANOGREAT Graphene NANOcomposites REActors at preindustrial Technology readiness Graphene
OPTNEWOPT Materials substitution in optoelectronic devices Electronics
SPARK Substitution and recycling of critical elements in materials for ionizing radiation detection
Electronics
QM-FORMa Designing New Materials with Quantum Mechanics Modelling
Modelling Factory Collaborative modelling, simulation and decision making through shared Modelling Factory
Modelling
Nan
oEl
ec-
tro
nic
sM
od
e-lin
g
NoI MetLight
Short Title Title Start Date End Date
AMIS AMIS Master Program 01.01.18 31.12.20
DiENT Digital Entrepreneurial Education Portal - DiENT 01.01.18 31.12.20
FAME-INNO FAME-INNO. Functional Advanced Materials and their Engineering-Innovation 01.01.16 31.12.17
SaferNanoDesign Summer School on Safer Design for Nanomaterials. 01.01.18 31.12.20
IDS-FunMat-Inno-2 International Doctoral School in Functional Materials & Innovation (2nd cohort) 01.01.18 31.12.19
RAMSES Advanced School on Critical Raw Materials Substitution for Energetics and Photonics 01.01.16 31.12.16
EIT Raw Materials Substitution – Education project portfolio
LightRight („not yetclassified thematically“)
Materials for lightweight design – how to treat them right 01.04.17 30.12.19
4L-Alloys (“Processing“)
Life Long Learning on Light Alloys: from Raw Materials to Sustainable Products 01.04.17 31.03.18
Master programs and PhD schools
Lifelong Learning*
*There are currently no projects classified as “Substitution” in BlueBook. There are, however, projects that thematically relate to the substitution theme but are currently classified, for example, as “Processing”. The above mentioned projects are examples of those.
EOL recycling
• Design for recycling
• Waste collection and logistics
• Dismantling and sorting
Recycling. Challenges and opportunities
AutoBat-Rec2020
Automotive Battery Recycling 2020 01.01.18 end of life product r.
DISPLAY Upscale of material recovery from display applications and Printed Circuit Boards
01.04.17 end of life product r.
ReSiELP Recovery of Silicon and other materials from End-of-Life Photovoltaic Panels 01.04.17 end of life product r.
WEEE REC Upscaling of key technology for a recycling facility for 30,000 t/a WEEE-concentrate
24.02.16 end of life product r.
OpTaRec Optimising the Tantalum Recycling Process through Conditioning of Raw Materials, Process Automation and Material Logistics
01.04.17 secondary ind. waste
SPL-CYCLE Closing the loop of the Spent Pot-line (SPL) in Al smelting process 01.01.18 secondary ind. waste
RADIUS Recycled automotive components by upgrading metallic scraps 01.01.18 secondary ind. waste
TiSPHERO Manufacturing of spherical powders from scraps for special applications 01.04.17 secondary ind. waste
ViviMag A novel magnetic route for phosphorus and iron recovery from sewage sludge 01.01.18 urban waste
PHOS-FORCE Market ready technologies for P-recovery from municipal wastewater 01.04.18 urban waste
Recycling – Up-Scaling project portfolio classified as “Recycling”
AVAR To produce a number of scarce raw materials for the European economy from wastes from the alumina refining industry.
V, Ga primary by-product
NewEco To produce a Ni/Cu/Co/PGM/S product from new sources of nickel sulphide concentrates (“mattes”
Ni, Co, Fe, Cu primary by-product
COPPLEX New Sustainable Process to treat Complex Raw Materials, Revaluating Residues
Cu, As primary by-product
MIN-PET Mineral Products from Petrit-T sidestream technology DRI, Ca, geopolymer
primary by-product
RIGaT Recovery if Indium, Germanium and Tin In, Ge, Sn primary by-product
RECOVER Red mud and Copper slag Valorisation in Engineered Products Cu, Al, Red Mud primary by-product
Go-4-0 From iron and manganese oxides wastes to valuable metal alloys using novel carbon sources materials
Steel, FeMn primary by-product
ReclaMet Reclaiming valuable metals from process residues with the HIsarnaprocess
Iron, Zn primary by-product
FLAME Fly Ash to valuable MinErals Fly ash secondary ind. waste
SELISI Second life of Silicon Si secondary ind. waste
REGENERATION Reusable Germanium wafers for the next high-Efficiency t-f solar cell geneRATION
Ge secondary ind. waste
Recycling – Up-Scaling projects classified as “Processing”
Zero Waste Cluster: “Material recovery from low grade, complex ores, wastes and residues requires an integrated approach combining different technologies for pretreatment, metal extraction and residue valorization.”
Recycling. Networks of Infrastructure
Broad range of markets; any type of low grade ore and waste.
Joint web site : http://www.zerowastecluster.eu
Joint participation in events
Joint dissemination actions
Recycling Portfolio – Education projectsCE-COSP Circular Economy and Raw Material Competence for Sustainable production 17065 PhD
IMAGINE-II Implementation of EIT KIC Raw Materials Master Programs in Sustainable Materials 17135 Master
AISS Alumni Interaction in the frame of dedicated Summer Schools 17157 Master
CARONTE Continuing educAtion and scientific infoRmatiON literacy on raw maTerials for profEssionals
16168 LLL
CIRRUS Circular Residue Usage in the Metallurgical Industry 16408 LLL
BizMet COMPETITIVE SUSTAINABLE BUSINESS FROM METAL RECYCLING 17127 LLL
PARADE Best practices for Pre-demolition Audits ensuring high quality RAw materials 17150 LLL
GAMES Great Adventures with Materials: Education for a Recycling Society 16282 WSL
BusiSource Waste from companies as a secondary source 16387 WSL
E-M@S E-Mining@school 17144 WSL
[email protected] Raw Matters Ambassadors at Schools 3.0 17146 WSL
AWARD RM Documentary: A Series of RM Documentaries followed by Interactive Workshops 17210 WSL
WM-CRM Blended learning Course Waste Management and CRM’s 17227 WSL
Recycling. Internationalisation, RIS portfolio
GloREIA Towards a Global Rare Earth Industry Association 17153 Internationalisation
RAISESEE Raw Materials Students Internships in East South East Europe 17167 Internationalisation
raPHOSafe Classification and Sorting of Radium-rich Phosphogypsum Tailings 17027 RIS