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

TL;DR

The CRUSADE project develops a sustainable recycling system for automotive waste to recover critical materials, supporting EU climate and digital goals.

Contribution

A novel hydrometallurgical process with AI and microwave-assisted leaching for efficient CRM recovery from ELV waste.

Findings

A hydrometallurgical process recovers 40 tonnes of CRMs annually from 500 tonnes of ELV waste.

Microwave-assisted leaching reduces CO₂ emissions by 15–80% compared to conventional methods.

AI and blockchain integration improves sorting accuracy and traceability in recycling.

Abstract

The European Union’s ambitions for climate neutrality and digital leadership rely on secure access to CRMs, essential for green and digital technologies but supply risks and geopolitical challenges. The CRUSADE project develops a sustainable, integrated recycling approach targeting underutilized waste streams from ELVs, including PCBs, catalytic converters, batteries and automotive fuel cells. CRUSADE proposes a universal hydrometallurgical process treating up to 500 tonnes of waste annually and recovering approximately 40 tonnes of CRMs at commercial purity. At the core of the process is a MWAL technology that enables a 15–80 % reduction in CO₂ emissions compared to conventional leaching methods, depending on feedstock composition. The process integrates AI-based automation for sorting and treatment, advanced downstream recovery and material traceability via digital tools, aligning with Industry 4.0 principles. Currently, the project is progressing toward scaling up these technologies to a modular pilot unit at TRL7, targeting 15 % faster processing time and 15 % lower product cost relative to current practices. CRUSADE aims to close material loops within the automotive and micromobility sectors, contributing to Europe’s circular economy objectives, raw material independence and climate mitigation goals under the European Green Deal.

•Microwave-assisted leaching improves recovery of critical raw materials (CRMs).•AI-driven LIBS sorting enhances accuracy and process efficiency.•Blockchain ensures traceability and regulatory compliance.•Flexible recycling handles batteries, catalysts, MEAs, and PCBs.•Supports EU goals for circular economy and CRM supply security.

Microwave-assisted leaching improves recovery of critical raw materials (CRMs).

AI-driven LIBS sorting enhances accuracy and process efficiency.

Blockchain ensures traceability and regulatory compliance.

Flexible recycling handles batteries, catalysts, MEAs, and PCBs.

Supports EU goals for circular economy and CRM supply security.

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