In many aspects batch processes are superior to continuous. Therefore it is worthwhile to take advantage of recent progress in sensor technologies, modelling and automation to develop a new paradigm for the design and conduction of batch processes: a) operation at maximum efficiency, b) dynamic, quality driven process trajectories rather than fixed schedules c) detailed analysis and tracking of all relevant process and product parameter. The main objective of the proposed project is the maximization of efficiency (reg. quality, energy, raw materials, and costs) of batch processes. Integrated process control is essential for an efficient operation of industrial batch processes: it tracks the evolution of product properties, detects deviations from the target values for product quality and derives corrective actions at a stage when an automatic compensation of deviations from an optimal trajectory is still possible. This contributes to optimal energy and raw material utilisation, shortens production time and enhanced the product quality. With the ambition to deliver solutions with relevance to all sectors of the process industries, the RECOBA consortium represents a selection of batch processes operating industries and partners across the value chain of batch process control, among them 3 global players from the polymer industry (BASF), the steel industry (TKSE), and the silicon metal industry (ELKEM). Within RECOBA there will be developed and validated: (1) new & innovative solutions for the measurement of different types of quality aspects, (2) new models to realise integrated process control of batch processes & suitable online parameter adaptation technologies to keep these models valid, (3) control modules to realise concepts for real-time, model based & closed loop process control, which are easily adaptable to existing batch processes in various industrial sectors, (4) business models to approach relevant industrial sectors for a future market entry.

Several materials are produced by carbothermic reduction, using fossil carbon as a raw material and with CO2 as an unavoidable by-product. Since the use of hydrogen does not generate CO2 emissions, hydrogen can be a solution for decarbonising these otherwise hard-to-abate industries. In-fact, hydrogen from renewable energy sources is expected to contribute to decarbonise a large part of the EU's metallurgical industry by 2050. However, since it is not as strong a reducing agent as carbon, there are several metals that cannot be produced directly with hydrogen. Some of these, such as silicon (Si) and manganese (Mn), are crucial for successfully building Europe’s clean technology value chains and meeting the EU’s 2050 climate neutrality goal. In fact, Si and Mn are both defined as Critical Raw Materials (CRMs) and Strategic Raw Materials (SRMs). The European Commission has proposed a regulation on that aims to strengthen the EU’s capacities and resilience along the CRM and SRM value chains. This cannot be done in a sustainable way unless production of CRMs and SRMs can be performed without CO2 emissions. The overall ambition of MECALO is to develop an innovative CO2-free production concept for CRMS where renewable hydrogen is used to eliminate the need for fossil carbon . Our goals are: - To target 95% reduction of CO2-emissions from Si and Mn production - To replace 9 million tonnes of annual coal imports by 15 billion Nm3 of H2 in 2050 - To save 33 million tonnes of annual CO2 emissions in 2050 Our concept will be applicable to all carbon reduction processes without any need for completely new, low TRL production technology. Therefore, MECALO will strengthen the EU’s capacities and resilience for a secured and sustainable supply of these CRMs. MECALO is gathering EU leading RTO and industries along the CRM value chain, including two major players in the field of Si and Mn production.

The core technological approach of the HYDRA project consists of using hybrid electrode technology to overcome the fundamental limits of current Li-ion battery technology in terms of energy, power, safety and cost to enter the age of generation 3b of Li ion batteries. HYDRA, taking its name from the mythological beast, will use a multi-headed integrative approach: In addition to novel material development and scale-up of components and battery cells manufacturing, assisted by modelling, HYDRA will build a synergy with strong investments by the project’s industrial partners and foster reaching and keeping a significant market share for Europe. The necessary competitiveness will be obtained by hybridizing high energy with high power materials. These materials will be implemented at the cell/electrode level, via sustainable, eco-designed scaled-up manufacture and safe electrolyte systems, demonstrated in pilot scale to TRL6, and will be ready for commercialisation 3 years after the project end. To reach this target, HYDRA mobilizes a strong industry commitment: the partners include a strong value-chain of suppliers with global competitiveness for xEV batteries and a direct liaison to the market in sectors such as automotive and maritime transport, ensuring a fast-uptake of results, with an added value of 1BN € in the next decade. Ecological and economical sustainability also keep a strong importance, as HYDRA will be performing life cycle assessments and value-chain analyses on local and global scales. All aspects from raw materials via battery cell production and end-use/market to recycling and 2nd life usage will be evaluated. The HYDRA concept uses abundant electrode materials like iron, manganese and silicon, and eliminates the use of the CRMs cobalt and natural graphite, with a net CRM reduction of >85%. The new materials will be produced in an environmentally friendly, energy-efficient manner, and using water in place of organic solvents.

Thermoelectric materials have been studied for several decades now. Improved TE materials are emerging with the so-called second-generation thermoelectric (GEN2 TE) materials: silicides and half-Heusler. These materials are low-cost, based on most earth-abundant elements and eco-friendly materials, and can impact positively European industry and society by converting wasted heat into electricity. As GEN2 TE materials are attracting a growing interest, pilot lines resulting from partnerships between public research institutes, industrial research teams and SME are emerging in Europe. The aim of the INTEGRAL project is to upscale the GEN2 TE material technology using existing pilot lines and growing SMEs, in order to address mass markets TE needs (automotive, heavy duty trucks, autonomous sensors and industry waste heat recovery). The INTEGRAL project is unique since it gathers in a complete value chain the major companies (including SMEs and startups) developing GEN2 TE advanced materials in Europe and cutting-edge research centers. INTEGRAL will allow the industry to step up towards advanced manufacturing and commercialization of systems integrating multifunctional TE materials (on a nano-based approach), through material customization, next techniques for characterization and process control and up-scaled pilot-line demonstrations of reliability, reproducibility and mastered material consumption. Furthermore, the large-scale processes which will be developed for producing nanostructured materials within the INTEGRAL project will explore a wider range of applications outside thermoelectrics, in particular where customization of electrical or thermal properties of sintered or casted materials are needed. Finally, a technology transfer will be performed from research activities to pilot-lines, towards the commercialization of the new generation of advanced materials with a circular economy vision.