CRUSADE project: Recycling technologies for ELV components to create a sustainable source of market grade materials for EU applications
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.
Authors
- Derya Dilara Atas
- Panagiotis Xanthopoulos (ORCID: https://orcid.org/0000-0002-5529-7476)
- Elena Santamariña
- Andreas Tsoumanis (ORCID: https://orcid.org/0000-0002-8512-4509)
- Naim DONMEZ
- Wambui Wamunyu
- Manuel Di Frangia
- Dimitris G. Mintis (ORCID: https://orcid.org/0000-0003-3002-951X)
- Alexandros Charitos (ORCID: https://orcid.org/0000-0003-2099-4957)
- Andrés Celare Fernández
- Vasiliki Zogali
- A. Katsiapi
- Florian Witzel
- Marco Passadoro
- Irene Gatto (ORCID: https://orcid.org/0000-0001-6950-6788)
- Flavio Parussa
- Camilo Prieto
- Olga Thoda (ORCID: https://orcid.org/0000-0002-4207-1152)
- Giovanna Nicol
- Anastasia Maria Moschovi (ORCID: https://orcid.org/0000-0003-3741-412X)
- Thomas Abo Atia
- Iakovos Yakoumis (ORCID: https://orcid.org/0000-0002-9018-7379)
- Antreas Afantitis (ORCID: https://orcid.org/0000-0002-0977-8180)
- Burak GUZELTEPE
- Diana Ferrara
- Deniz Koç
- Lucas Brockerhoff
- George Paloumpis
- Eleni Papadopoulou
- Lesia Sandig-Predzymirska
- Dominique Von Sivers
- Francesco Veglio
- Sebeh Adjapong
- Bjorn Gieseking
- Walter Murru
- Peter Weber
- Jendrik Kromminga
- Mehmet Çelik
- Carmelo Lo Vecchio
- Philippe Lavoie
- Andrea Vincenzo Abbate
- Renzo Costa
- Michela Spreghini
- Svetlana Zueva
- Vincenzo Baglio
- David Anguera Sempere
- Panagiota Stamatopoulou
- Lydia Gerolymatou
- Francesco Di Muro
- Farzad Salehi
- Rosanna Babagiannou
- Nikolaos Theodoropoulos
- Yiğitcan Kama
- Özak Durmuş
- Epameinondas Athanasakopoulos
Institutions
- nLIGHT (United States) (US)
- Consolidated Contractors Company (Greece) (GR)
- Frederick University (CY)
- Larnaca College (CY)
- Helios Klinikum Krefeld (DE)
- Asociación de Investigación Metalúrgica del Noroeste (ES)
- Torino e-district (IT)
- Smart Solution (Norway) (NO)
- Ingegneria dei Sistemi (Italy) (IT)
- Deutsche Montan Technologie (Germany) (DE)
- Consorzio Roma Ricerche (IT)
- Ford Otosan (Turkey) (TR)
- Azienda Sanitaria Locale Roma 3 (IT)
- Advent Technologies (Greece) (GR)
- TU Bergakademie Freiberg (DE)
- KU Leuven (BE)
Publication Details
- Journal
- Computational and Structural Biotechnology Journal
- Published
- 2025-12-25
- DOI
- https://doi.org/10.1016/j.csbj.2025.12.016
- Primary Topic
- Recycling and Waste Management Techniques
- Type
- article
- Field-Weighted Citation Impact
- 0.00