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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



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



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


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


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

http://www.zerowastecluster.eu/

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