The main achievements for each activity of the project are:
1/ Recovery of critical raw materials from mining wastes and wastewater: Partner CETAQUA first characterized the samples of acidic and solid waters from the mining demonstration site to determine which points are of greater interest to recover critical materials. In parallel, we designed two treatment trains to recover valuable metals from wastewater and mining waste, respectively. The first is located at CETAQUA facilities and consists of a non-ferrous metal recovery unit followed by an adsorption module with a final crystallizer. The second is located at THARSIS facilities and consists of a thermal waste valorization unit. These treatment trains are now operational, and the demonstration and techno-economic analysis of the process are ongoing.
2/ Sustainable silicon production: RESILEX has demonstrated a sustainable silicon recycling process at lab and medium scales. NTNU developed a circular method using aluminothermic reduction of quartz fines, refining silicon from recycled sources like Si-kerf and slag. This process achieved 97.79% purity at 100 kg scale. Further refining through directional solidification and Czochralski (Cz) growth led to 3N–5N purity, with 5N in the ingot’s core. CEA produced three 30 kg Cz ingots using up to 12% recycled silicon, achieving dislocation-free growth. One ingot was sliced into 700 wafers for WP4. Life Cycle Assessments (LCAs) are ongoing to evaluate carbon footprint reductions compared to global averages.
3/ Sustainable, eco-designed solar cells & modules: An industrial SHJ solar cell process was developed, eliminating indium via aluminum zinc oxide (PVD) and reducing silver through copper-based screen-printing. This led to just a 1.4% efficiency loss compared to the reference. Additional SHJ cells with 72% less indium and copper metallization (via printing and plating) achieved high performance with efficiency ≥25%. Initial Life Cycle Costing showed a 10% cost reduction, with potential for more savings through new materials. Early LCA results show a 46% carbon footprint cut by replacing alumina frames with wood and using polymer-glass alternatives for front covers.
4/ Silicon recycling from PV modules: In RESILEX, silicon material out of Silicon cells recovered from PV panels (provided by Recma and ENVIE2E) will be used to make batteries and/or new Silicon wafers. The technical specifications to meet the targets of the recycling process is now finalised. The design of the upgraded process is done. Results at small-scale already validated the possibility to reuse Silicon for anodic material. For wafers use, a higher purity is needed (9N). The demonstrator will be started up before Q4 2025.
5/ Development of high-efficiency Si composite for Li-ion batteries: RESiLEX developed and optimized the process allowing the production of Si/C composite at pilot-scale with a production capacity exceeding 1 Kg per week (MS9). Furthermore, as detailed in the Deliverable D6.3 and briefly described in T6.3 RESiLEX has successfully accomplished the SO5 by preparing the 20 multi-layer pouch cells. These cells incorporate 10 wt.% Si/C composite sent by ULIEGE-GREEnMat, designated as MS9 (T6.2) at the anode side achieving a capacity exceeding 2 Ah. Electrochemical testing is currently underway at CEA and is scheduled to start shortly at CSEM.
6/ Multi-faceted Impact assessment & EU policy recommendations: The perimeter of analysis and assessment of the different pilots have been defined and the first version of the RESiLEX Policy Platform where policy recommendations will be released has been launched. The stakeholder questionnaire remains open to gather further inputs to draft RESiLEX’s recommendations. A policy brief with recommendations for the EC has been developed between RESILEX and 5 other Horizon-funded projects focused on sustainability of the production of PV panels
