SusChem and ISC3 sign MoU to advance Sustainable Chemistry

The European Technology Platform for Sustainable Chemistry (SusChem) and the International Sustainable Chemistry Collaborative Centre (ISC3) signed a new cooperation agreement to foster their common mission of advancing Sustainable Chemistry at a European and global level at the recent SusChem board meeting on 14 March 2019 in Brussels.

The Memorandum of Understanding (MoU) outlines the role of each organisation and proposes long-term collaboration in the following areas: research agenda development, fostering breakthrough Innovation, education & skills development and stakeholder dialogues on Sustainable Chemistry. Through this agreement, both parties aim to maximise the impact of relevant activities, build on synergies and complementarities, and create added value for their members.

Markus Steilemann, Chairman of the SusChem board (pictured above, left), said:

“The memorandum reflects the commitment of both sides to work together towards advancing sustainable chemistry innovation to address EU and global challenges. In the course of 2019, we look forward to collaborating on the new SusChem Strategic Research and Innovation agenda (SIRA), and on the ISC3-led ‘Global understanding of Sustainable Chemistry’ consultation. Here,  SusChem brings in the European perspective sharing the benefits of our SusChem network of National Technology platforms.”

Friedrich Barth, Managing Director of ISC3 (pictured above, right), said:

“We join forces with SusChem to promote sustainable innovation in the chemical sector, leveraging a multi-stakeholder approach that involves Academia, SMEs, start-ups, the large Industry and society. Working with SusChem means having on board such a European forum, building on existing knowledge and advancing Sustainable Chemistry, not only at a European level but at a global scale, which is our main mission.” 

A key 2019 priority of this agreement is the bilateral input on Research Agendas. 

The new SusChem Strategic Research and Innovation agenda (SIRA), is currently being revised and will be structured in line with the next EU research and innovation framework programme: Horizon Europe (HEU). The SusChem SIRA will also address the impact of Sustainable Chemistry on global challenges, as part of HEU, and therefore the Sustainable Development Goals (SDGs). ISC3 will provide input on all relevant technology priorities, and the potential impact of such innovation in Sustainable Chemistry with regards to global challenges. ISC3 will also provide key input on priorities under education and skills, a horizontal topic that will be covered in the new SusChem SIRA.

SusChem will provide input to the ISC3-led ‘Global understanding in Sustainable Chemistry’ consultation with a strong focus on Europe. SusChem will also involve the SusChem NTP network (17 countries) to provide a national perspective.

About SusChem

SusChem ETP, founded in 2004, is a European Technology Platform, with the main objective of contributing to revitalising research & innovation in Sustainable Chemistry and Industrial Biotechnology in Europe. As a multi-stakeholders networking forum and a technology solutions provider, SusChem works towards advising on technology priorities, at a European level, with a long-term strategic research and innovation agenda (SIRA). Connection to National priorities is achieved via its network of  National Technology platforms. SusChem engages, consults and brings together representatives from larger Industry, SMEs, Universities and research technology organisations – being open to the wider society. SusChem technology focus areas include:  Advanced Materials, Advanced Processes, Catalysis, enabling Digital technologies as well as Horizontal topics.

About ISC3

ISC3, founded in 2017, was established by the German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety (BMU) and the German Environment Agency (UBA). ISC3 has a structure supported by a Research & Education Hub (Leuphana University, Lüneburg) and an Innovation Hub (DECHEMA, Frankfurt) with the aim to also establish regional hubs outside of Europe. It is a globally acting institution, a multi-stakeholder platform and think tank that engages with the private sector, civil society and politics to contribute to international chemicals policies and the formation of a global network for collaboration, innovation and education on Sustainable Chemistry. Activities to achieve such objectives are: dialogues amongst stakeholders, building on a global start-up service and funding, developing a Sustainable Chemistry curriculum, and also working towards a research agenda outlining a common understanding on Sustainable Chemistry, sustainability assessment and cross-sectorial topics.

Both platforms share the intent of contributing to a more sustainable world and a circular economy, and to the transformation of the chemical sector towards sustainable chemistry, responding to global challenges.

REE4EU Pilot Plant success

The SusChem-supported Horizon 2020 project REE4EU has successfully demonstrated at a pilot scale a closed-loop permanent magnet recycling process for the first time in Europe. The REE4EU pilot has successfully treated several tons of in-process wastes and end-of-life magnetic products containing rare earth elements, resulting in the recovery of almost hundred kilos of rare earth alloys. The alloy will be reused in the manufacturing of permanent magnet products, thereby closing the materials loop!

The successful recycling of permanent magnet waste is a major result for the REE4EU SPIRE project whose full title is: Integrated High Temperature Electrolysis (HTE) and Ion Liquid Extraction (ILE) for a Strong and Independent European Rare Earth Elements Supply Chain.

Rare earth elements (REEs) are the seventeen chemical elements including the lanthanides, Scandium and Yttrium that are key-enablers of sustainable technologies. They are used in hybrid electric vehicles, wind turbines, and highly efficient electric motors. Currently European industries are highly reliant on imports of these valuable and rare materials. Recycling the elements from REE-containing waste streams could constitute an important secondary source of the materials for Europe.

A recent study estimated the global trade in REE-containing products in 2010 is around EUR 1.5 trillion, or 13% of global trade. However, only 1% of REE waste is being recovered as no adequate process is currently available. REE4EU’s success could open-up a brand-new route to recover process wastes from permanent magnet production.

Pilot demo

During the third year of this four-year project that started in October 2015, work has focused on constructing and running the REE4EU's pilot units: the high temperature electrolysis (HTE) and ionic liquid extraction (ILE) units. The technology has now been demonstrated at pre-industrial scale using permanent magnet wastes.

Enough waste material (in-process waste and end-of-life magnets) has been treated to obtain enough rare earth alloy (REA) to run a 600 kg batch of strip cast rare earth master alloy (REMA) and output material from the HTE pilot cell has been used to manufacture permanent magnets in a laboratory line.

The quality of both the REMA input and the permanent magnet output obtained in terms of magnetic properties and chemical composition show that the magnets prepared have the same properties as magnets from mass production using virgin materials. This validates the REE4EU technology to obtain REA for permanent magnet production using magnet waste materials.

The two-step process (ILE then HTE) has been optimised for direct REA production, suitable for REMA to be used in permanent magnet manufacturing. In this way, a complete closed-loop permanent magnet recycling has been demonstrated at a pre-industrial scale using less steps than conventional methods currently carried out in China.

The process and its advantages are explained in this REE4EU video.

Next steps

In the next few months, the REA obtained in the HTE unit will be used to manufacture REMA for permanent magnets in a real magnet production line and benchmarked against magnets produced using virgin materials.

Data collection and modelling activities on permanent magnet waste recycling routes have been carried out and these results will be used to eco-design the recycling chain and to compare it to the conventional supply route of REA currently used for permanent magnet production.

For more information on the REE4EU processes visit their website.

VERAM delivers

The SusChem supported Horizon2020 project VERAM (Vision and Roadmap for European Raw Materials) brought together diverse stakeholders – including five European Technology Platforms (ETPs): Sustainable Mineral Resources, Forest, Construction, Sustainable Chemistry and Advanced Materials – to produce a medium-term (2030) Vision and a longer-term (2050) Strategic Research and Innovation Roadmap for raw materials. VERAM is now completed and its public project deliverables are available to download.

Demographic changes, such as population growth in developing countries and an ageing population in developed countries, coupled with increasing standards of living and urbanisation trends will foster a greater demand for products and applications linked to human well-being, health, hygiene and sustainability. As a consequence, the worldwide demand for raw materials is expected to increase while global resources and land become scarce. A shift towards a more resource-efficient, circular economy and sustainable development is essential. 

Europe is confronted with many challenges along the entire raw materials value chain. Yet, innovation in raw materials value chains remains untapped despite the sector’s great potential.  A more coordinated approach towards raw materials management will help reduce external supply dependency and lead to an efficient use of resources.

To achieve these goals, a long-term vision and roadmap to 2050 could help tap the full potential of raw materials supply and use in Europe and boost the innovation capacity of the sector, turning it into a strong, sustainable pillar of the EU economy and an attractive industry, whilst addressing societal and environmental challenges and increasing benefits for society. This is where VERAM came in.

Key to success

“The key to the success of VERAM was the strong partnership that was forged through the project, linking diverse ETPs, value chains, industry sectors and academia,” commented Patrick Wall, VERAM’s project coordinator from the European Technology Platform on Sustainable Mineral Resources (ETP SMR).

“To address the challenges in the raw materials supply chain, VERAM initiated communication and dialogue between the different raw materials sectors, stakeholders (including civil society organisations) and all parts of the value chain to pool experience and knowledge and build the VERAM Vision and Roadmap for Raw Materials,” Mr. Wall continued.

Henk Pool, Innovation Manager at CEFIC, a partner in the VERAM project consortium said: “Predicting the future is a significant challenge, especially in a world that is experiencing rapid change, including accelerators of change such as digitalisation, however we can be certain that there will still be a significant need for raw materials in 2050! And VERAM has helped us understand what will be required and the critical need for innovation to ensure this need can be met.”

Deliverables to download

A range of deliverables across the project’s five work packages are now publicly accessible. They include:

Work package 1: Management and coordination

• Results of the feasibility study to establish a R&I Raw Materials Stakeholder Portal

Work package 2: Dissemination and communication

• Project website design and initial promotion materials (logo, templates)
• Clustering with ongoing initiatives (EIT RM; clusters; EU projects on RM, …)
• Final Conference

Work package 3: Defining and exploring the playing field

• Report on the raw materials research and innovation network: the relevant players and their roles
• Report on the RM research & innovation funding and projects: relevant R & I topics in the EU and abroad, strengths and weaknesses of current EU and MS funding landscape
• Report on future societal challenges and the corresponding needs of global markets and EU industries
• Report on the challenge ahead: the gap between future EU industrial needs and current research and innovation funding
• Web based information handling portal

Work package 4: Creating a vision 2030 and 2050 for raw materials

• Report on economic outlook and raw material needs for 2050
• Report on Raw material research and innovation vision for 2050
• Report on innovation and capacity building needs across the EU economy till 2050

Work package 5: Creating the raw materials roadmap 2050

• RM Research Roadmap drafts
• RM Research Roadmap and recommendations

KETs Impact: The CONSENS Project

The recent SusChem White paper ‘Impact: Key Enabling Technologies (KETs) in Horizon Europe’ included a number of success stories highlighting publicly funded innovation involving KETs and the SusChem News blog is featuring a selection of these fruitful 'SusChem inspired' initiatives.

KETs are technologies selected for their ability to address global challenges, support the development of new products, and stimulate economic growth.

Sustainable chemistry is essential to the technological advance of KETs including advanced materials, advanced manufacturing technologies, industrial biotechnology, micro and nanoelectronics, nanotechnology and photonics. SusChem's key enabling technologies provide the critical building blocks for the solutions needed to achieve a sustainable low carbon circular economy. You can find out more here.

Our first highlighted success story is on the SPIRE Horizon 2020 project CONSENS (Integrated Control and Sensing for Sustainable Operation of Flexible Intensified Processes) that has paved the way for the factory of the future by developing novel sensors and integrated process control techniques.

Sustainable operation of flexible intensified processes 

Digital technologies enable the migration from batch to flexible continuous intensified processes

Public funding facilitates the fruitful collaboration of seven companies from the chemical industry and eight excellent European partners from academia, research and technology

The future competitiveness of the European chemical industry depends on its ability to deliver high quality and high value products at competitive prices in a sustainable fashion, and to adapt quickly to changing customer needs. The use of flexible intensified continuous processes is a promising strategy towards this goal, because they give access to new and difficult to produce chemical compounds, lead to better product uniformity and reduce the consumption of raw materials and energy drastically. Moreover, it facilitates flexible and mobile production in more efficient and smaller plants and enables companies to bring new products quickly to the market. As an analysis within the former SusChem flagship project F³ Factory has shown, a fully automated process operation is a prerequisite to realise these benefits.

Therefore, the main goal of the CONSENS project was to advance the continuous production of high-value products that meet high quality demands in flexible intensified continuous plants by introducing novel digital technologies such as: new online sensors with capabilities that are not available on the market, novel closed-loop control methods for flexible operation and high-quality levels, as well as data-based and simulation-based methods to ensure optimal operation of the controlled system.

How was the breakthrough innovation achieved? 

The development work was steered by the needs of the industrial partners. Three commercially relevant case studies were selected that reflect the requirements: an intensified pharmaceutical synthesis, a continuous polymerisation process, and the continuous formulation of complex liquids. The key success factor was to consider sensors, closed-loop control, monitoring solutions, soft-sensors, and process dynamics in an integrated approach. This led to holistic control solutions that were validated very successfully in the pilot plants.

KETs

Impact
From the results achieved in the three case studies, we can conclude financial savings of EUR 265 million/year, a reduction of CO2 emissions by more than 490 000 tonnes/year, and less consumption of non-renewable raw materials of 176 000 tonnes/year in the related industries in Europe by enabling the migration from traditional batch processes to flexible intensified continuous processes.

It is expected that the market share of European chemical production plants on the global market will increase by ca. 3% due to better quality, innovative products and higher competitiveness.

More information
CONSENS – Integrated Control and Sensing for Sustainable Operation of Flexible Intensified Processes (Horizon 2020/ SPIRE GA number 636942).

Read the SusChem White Paper ‘Impact: Key Enabling Technologies (KETs) in Horizon Europe’