Recycling technologies for ELV components to create a sustainable source of market grade materials for EU applications

Project Information

CRUSADE

Grant agreement ID: 101138642

DOI

10.3030/101138642

EC signature date 28 November 2023

Start date 1 January 2024

End date 31 December 2027

Funded under

• Digital, Industry and Space

Total cost

€ 8 770 962,35

EU contribution

€ 6 956 943,75

Coordinated by

MONOLITHOS KATALITES KE ANAKIKLOSI ETAIREIA PERIORISMENIS EVTHINIS
Greece

Periodic Reporting for period 1 - CRUSADE (Recycling technologies for ELV components to create a sustainable source of market grade materials for EU applications)

Reporting period: 2024-01-01 to 2025-06-30

Summary of the context and overall objectives of the project

The CRUSADE project addresses the urgent need for sustainable and economically viable solutions for the recycling of critical raw materials (CRMs) from end-of-life vehicles (ELVs), in alignment with the EU’s Green Deal, Circular Economy Action Plan, and CRM Resilience Strategy. Modern vehicles integrate an increasing number of components containing CRMs—such as autocatalysts, fuel cells, batteries, and printed circuit boards—which, when discarded, represent both an environmental burden and a missed economic opportunity. CRUSADE is designed to recover these valuable materials while significantly reducing the carbon and energy footprint associated with conventional recycling methods.

CRUSADE aims to upscale and integrate novel hydrometallurgical technologies to Technology Readiness Level (TRL) 7, demonstrating their technical and economic viability through a pilot-scale facility capable of treating 500 tonnes/year of spent automotive components. The process targets the recovery of approximately 40 tonnes/year of CRMs including Cu, C, Co, Mn, Ni, Pt, Pd, Rh, Li, and Ru at commercial-grade specifications. This is achieved through a complete end-to-end system combining optimised pre-treatment, microwave-assisted leaching, and downstream purification methods such as solvent extraction and electrowinning.

To ensure long-term impact, CRUSADE leverages a pan-European collection network and industry partnerships with key players in the automotive and recycling sectors. It incorporates blockchain-based material tracing and AI-driven automation aligned with Industry 4.0 principles. This results in a system that is not only environmentally friendly—offering up to 80% reduction in CO2 emissions—but also commercially competitive, delivering recycled materials at 15% lower costs than current market prices.

By fostering innovation in CRM recovery and enabling circularity in the automotive supply chain, CRUSADE supports the EU's strategic autonomy, reduces dependency on primary imports, and contributes to greener industrial manufacturing. The project also incorporates socio-economic and policy analyses to ensure that the developed technologies are scalable, inclusive, and aligned with evolving regulatory frameworks and societal expectations.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

WP3 – Established robust collection, sorting, and blockchain traceability for EoL catalysts, batteries, PCBs, and MEAs. TRON-based smart contracts log process events with immutable, on-chain metadata. Collection networks set up via multiple partners, with MONOLITHOS processing >40,000 catalysts/year and securing MEA supply. AIMEN/ENTE developed AI + LIBS sorting and the MetalXtract PCB classification platform. Over 1 t of EoL materials collected and characterised for downstream processes.

WP4 – Optimised pre-treatment of batteries, PCBs, and autocatalysts. ACCUREC dismantled/discharged 76 PHEV modules (750 kg NMC, 250 kg LFP black mass), recovering 79 kWh to the grid. TUBAF improved discharge safety/efficiency; BFC optimised acid leaching (substrates/components); MONOLITHOS refined sorting and thermal cleaning for improved PGM recovery.

WP5 – Demonstrated MW pre-treatment benefits in graphite flotation (92 % grade, 95 % recovery for NMC). MW-assisted leaching achieved 97 % Pt and 98 % Rh recovery from autocatalysts in 30 min; Pt/C electrocatalyst leaching reached Pt 86 %, Ni 95 %. Delivered 1 t of active powders, validated PCB/autocatalyst pre-treatment, and prepared for scale-up.

WP6 – Began early alignment of upstream outputs with downstream purification. Defined industrial benchmarks for fuel cell catalysts (>99.5 % H2PtCl₆, 20–30 wt.% Pt, >50 m²/g ECSA). Designed SX flowsheets for PGM separation, initiated precipitation/electrowinning for Li, Co, Ni, Mn, and Cu recovery.

WP7 – Designed functional architecture for real-time analytics, adaptive modelling, and robotic integration. Built PostgreSQL database with harmonised data standards. Mapped workflows, defined robotic intervention points, and prepared ROS-based control modules for integration with AIMEN conveyor and in-line LIBS/MSI.

WP8 – Defined synthesis and validation protocols for PGM catalysts, batteries, and PCBs. Prepared automotive-level testing for DOCs, autocatalysts, and NMC/LFP pouch cells from recovered materials. Established harmonised ISO-compliant LCA/LCC framework with “Gate-to-Cradle” scope, defined impact categories, and aligned cost structures.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Across WP3–WP8, the project has delivered results with strong potential to go beyond the current state of the art by combining novel blockchain-based traceability for EoL CRM streams, AI-driven automated sorting with LIBS and machine vision, optimised pre-treatment protocols for diverse feedstocks, and microwave-assisted leaching achieving near-complete PGM recovery in record times. These innovations, coupled with advanced flotation for graphite recovery, early integration of solvent extraction microfluidics, and the development of an interoperable Industry 4.0 framework for real-time process modelling and robotic intervention, provide a step-change in efficiency, selectivity, and scalability for CRM recovery. Early validation work in WP8 shows that catalysts, battery materials, and PCB coatings derived from recovered CRMs can meet or surpass the performance of virgin-material equivalents, while harmonised LCA/LCC methodologies set a benchmark for transparent sustainability assessment. To ensure uptake, further work should focus on scaling pilot results to industrial capacity, securing investment and IPR for key process innovations, engaging end-users in automotive, electronics, and energy storage sectors, aligning with EU recycling and product regulations, and building international supply chain partnerships to accelerate market entry.

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