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.