CLOSING THE LOOP · Thematic domain of the demo-case The main objective of the De-and...

CLOSING THE LOOPPromuovere l’economia circolare nella Regione Marche

Ancona, 8 marzo 2019

Golboo Pourabdollahian, PhD

CNR-STIIMA

CLOSING THE LOOP - Ancona, 8 marzo 2019

Vanguard is a political initiative of 30 European Regions aimed at the implementation of

strategic innovation projects in a logic of smart specialization

• 5 Pilot projects:

• ESM-Efficient and Sustainable Manufacturing

• 3DPrinting

• Energy applications in harsh environments

• Nano-enabled products

• Bio-economy

• Overall, the pilot projects generated

20 demo-cases aimed at the establishment and

exploitation of a highly specialized European

network of regional pilot plants

Envisaged pilot plants: Vanguard Initiative

Thematic domain of the demo-case

The main objective of the De-and Remanufacturing pilot network is to integrate a multidisciplinary set of advancedand innovative enabling technologies and digital innovations (TRL 7-8) and to exploit the regional SmartSpecializations in synergic way to offer services to European end-users, mainly manufacturing companies, to solvespecific sustainability-oriented problems related to their products.

The pilot network nodes will act as Innovation Hubs for Circular Economy (Circular Innovation Hubs), being a networkof competence and technology centers and supporting future producer-driven replication at industrial scale (TRL 9).

Selected within Pilot actions for "Interregional innovation projects” by the DG Regio

Pilot services

Industrial Innovation Service Portfolio

Reverse logistics optimization. Technical feasibility assessment.

Product Life-cycle information management. De-and Remanufacturing Process-chain design and demonstration.

Environmental sustainability assessment and LCA. System integration and control.

Patent and technology IPR searches. Product design/re-design for circular economy.

Market analysis and business models. Prototyping and product testing.

Legislation review and innovation deals. Production of pre-series.

Product and process certification. Process chain optimization, simulation, and analytics.

Business case validation and scenario analysis. Value-chain integration.

Circular economy training. Support to Environmental Technology Verification (ETV) applications.

The Pilot Network is seen as a One-stop-shop for delivering innovation services to the industrial end-users witha multi-regional approach.

Cross-Regional pilot network configuration

Use-cases (or industrial applications)

addressed in the demo-case

Regional/Cross-Regional Use Case Involved Regions

Composite Recovery from Wind Energy System Basque Countries, Saxony, Lombardy, Tampere, Scotland

Heavy machinery components remanufacturing Tampere, Basque Countries, Lombardy, Saxony, Emilia Romagna

Automotive parts remanufacturing Scotland, Lombardy, Saxony, Norte

High-value TLC systems and Electronics Recovery Lombardy, Tampere

Metal components reprocessing Saxony, Tampere, Lombardy, Wallonia

Remanufacturing of e-motors Saxony, Lombardy

Plastics recycling and re-use in electornics Flanders, Lombardy, Wallonia

Automotive Li-Ion batteries disassembly, remanufacturing and re-assembly for second use Lombardy, Saxony, Basque Countries

Photovoltaic panels de-manufacturing Flanders, Lombardy

Machining equipment retrofit and upgrade Emilia Romagna, Lombardy

Manufacturing of metal-sponge catalysts from aluminum waste material for chemical catalysts. Emilia-Romagna, Lombardy

Recovery of both metallic and non-metallic parts of slags, incinerator bottom ash, leaded glass - closing the materialloop.

Wallonia, Lombardy, Basque Countries

A detailed analysis of identified sectorial Use Cases, with industrial partners associated, has been performed, where more regions areinvolved. For each Use Case, a business case has been detailed including a business plan for the industrial take-up of the solutions.

Who is working at the use cases?

Cross-regional value-chain approach:

Lombardy: Li-Ion battery testing, disassembly and remanufacturing for second-use. Mechanical cell cutting processes for recycling.

Saxony: battery pack and module re-design for disassembly and remanufacturing.

Basque Country: Material recovery processes.

Second-life stationary systems (renewableenergy, home, office)

E-mobility

Goal: a new process-chain for the re-use of Li-Ion battery cells under a circular economy perspective, with a cross-sectorial approach.

Collection and pack dismantling

Use-case 8: E- mobility batteries remanufacturing for re-use


Title: Circular Economy oriented services for re-use and remanufacturing of hybrid and electric vehicles

components through smart and movable modules

Acronym: CarE-Service

Topic: Systemic, eco-innovative approaches for the circular economy: large-scale demonstration projects (CIRC-1-

2017)

Type of Action: Innovation Action

Date of Submission: 05/09/2017

Funding: 6.229.505€


Case Description: E-waste is the fastest growing stream in Europe (Estimated CAGR of 20.6% between 2015 and 2020) with a high variabilityin composition and evolution rate of products.

State of Art: Recycling of post-use electronic products by monolithic and rigid recycling processes.

Market opportunity: Post-use electronics as a source of high-value re-usable components and materials.

Objective: Investigate innovative de- and re-manufacturing process-chains to recover functions and materials (e.g. key metals, rare earths)from high value post-use electronics.

Italtel is an Italian TLC company design, developsand implements, electronic products and solutions for Next-Generation Networks services.• 24 millions of telephone lines installed worldwide and 8

millions of hardware units (boards, shelves, cabinets).• 80% of them are still working and expected to be dismissed

in the next years.

Goal:•Re-use components.•Recover high-value materials.

Expected Impacts:•8M€ increase in revenues per year for thecompany.

• Pay back time of the investment is 2 years.

Use-case 4: High-value TLC systems and Electronics Recovery


Use-case 4: High-value TLC systems and Electronics Recovery

SMART DISASSEMBLY

HYDROMET. PROCESSES

METALFRACTION

NON-METALFRACTION

RECOVERED VALUABLE KEY- METALS

SMART MECHANICAL

PROCESSES

RE-PROCESSING

PRODUCTS CONTAINING RECYCLATES

RE-USABLE COMPONENTS

INSPECTION MATERIAL CHARACTERIZATION SMART SORTING

Innovative process-chain

Technological Challenges:

• Adaptability to different post-use product conditions.• Higher level of automation.• In-line material characterization.• New service-oriented business models.

Cross-regional value-chain approach:

Lombardy: Mechanical pre-treatment, materialcharacterization, hydrometallurgical recovery.

Tampere: Application of the process-chain to other electronic products (mobile phones).

2.2 Who is working at the use cases?

More than 65 European companies, with a cumulative turnover of 32 B€ and with some 175,000 employees, and 72 universities andRTOs distributed among the involved regions are involved.TECforceCandy

ItaltelCEG

BarcoWorldilneTurner Aviation

Cargotec Finland OySandvik Mining and Construction OyMetso Minerals Oy

Valmet Power OyJohn Deere Forestry OyBronto Skylift Oy AbAvant Tecno OyHambleside Danelaw

Arup

FastemsTenovaMaierIndevaDMG Mori

Comet TraitementsCarmeuse

Filartex SpaGafitexPass MagliaSamatexPTMT PANTERRivierascaBrianza Plastica S.p.A.Sintostamp S.r.l.Magniplast S.p.A.OCV OwenscorningCovestroCampineGalloo PlasticsKokkola LCC OyA2A AmbienteRelightFincoat OY

Telatek Oy

Siae

Batz

Ki-lab

Weir Group

Marechal Ketin

Gamesa Siemens

Xnext

Lot Quantum Design

MH Systems

Holonix

Idealtech

Cosberg

Vibram

AERNNOVA

ITP

Galloo

Van Gansewinkel

TKM TTT Finland Oy

IRIZAR

Meleghy Automotive

GKN

Enginsoft

MCT Reman

Cobat

ASPIRE Eng.

Hydrométal

Magotteaux

The stakeholders have signed Letters of Intent to participate to the definition of this Pilot Network and, in the case of future end-users, to access thepilot network and to carry on industrial take-up, in case of positive evaluation of the developed solution.


Region IndustrialsectorManufacturer/Demanufacturer

TechnologyProviderUniversity/ResearchCentre/Associations

Lombardy

ElectricandElectronic

Equipmentandwhitegoods

Italtel,

Candy,Electrolux,Rold

Electronics,Whirlpool Xnext,LOTQuantum

Design,MHSystems,

Idealtec,Giasini,

Cosberg,Holonix,A2A,Indeva,

Nationalsystems,

Enginsoft,GFM,CSM

GruppoRina,Holonix,GreenCoat.

PolitecnicodiMilano,CNR,

UniversitàdiBergamo,AFIL.

Automotive&Transport MagnetiMarelli

CompositeManufacturingRivierasca,BrianzaPlastica,Sintostamp,Magniplast,Polynt

TextileIndustryFilartex,Gafitex,PassMaglia,Samatex,PTMTPANTER,

Marzotto,CSC,Vibram

Recycling Relight,Ki-Lab,Tenova,Cobat,CEG,SIAE.

Tampere HeavyMachinery

CargotecFinlandOy,SandvikMiningandConstructionOy,

MetsoMineralsOy,Valmet

TechnologiesOy,JohnDeere

ForestryOy,BrontoSkyliftOyAb,AvantTecnoOy

KokkolaLCCOy,

FincoatOy

TelatekOy

TKMTTTFinlandOy,Fastems.

TampereUniversityof

Technology,VTT,

TechnologyIndustriesof

Finland.

SaxonyAutomotive

KWD,MeleghyAutomotive,EDAG,INVENT FraunhoferIWU

MetalProcessingIndustry AFV,SIFE,STI,LRP

BasqueCountry

Automotive&TransportMercedes,GKN,IRIZAR,Batz,Maier

TecnaliaWindEnergy Gamesa

Aeronautic AERNNOVA,ITP

Flanders

Recycling Galloo,VanGansewinkel

KULeuven

Electronics TPVision,Barco,Worldline

PlasticscompoundingCovestro,Campine,Galloo

Plastics

Moulding Teco,Quadrant

ScotlandAutomotive,Aerospace,

WindEnergy,Construction,

Textile

AutocraftDrivetrainsolution;TurnerAviation,TurnerWind,

WeirGroup,Hambleside

Danelaw,Scott&Fyfe

DGMMori,Weir

Group,AutocraftDrivetrainsolution,

ConstructionScotland

InnovationCentre,

MCTReManLtd,AspireEngineering.

UniversityofStrathclyde,

ScottishInstitutefor

Remanufacture(SIR),Technology&Innovation

Centre(TIC),NPLScotland,

TheCentreforUltrasonic

Engineering(CUE),AFRC-AdvancedFormingResearch

Centre.

Norte Automotive,ToolingSimoldes,Palbit,Gestamp,

Alfais,PortugalSteel.

ADIRA,MotofilRobotics,RoboPlan,

SARKKISRobotics,

AMOB.

INESC-TEC,CATIM,ISQ,

INEGI,PRODUCTECH,

AINMAP,AFIA,Cefamol.

Emilia-RomagnaMachinetoolsmanufacturerJobs,Mandelli,Pama

MUSPlab,Politecnicodi

Milano(PiacenzaCampus)Machinerefurbishment SAMU,Over

WalloniaRecycling

Smelter

CometTraitements,

Hydrométal,Carmeuse,MarechalKetin,Magotteaux

CitiusEngineering ULIEGE,CRMGroup,CTP

Lombardy working group

ScotlandKey Issue: integrated pilot plant solutions, needed by industry to validate high-risk investments in circular economy businesses before the industrial implementation.

Totally new pilot site (or connection)

Upgraded existing pilot site (or connection)

Wallonia

Metallurgical processing to recover metals and valuable components

3 – Envisaged inter-regional nodes configuration

An integrated Pilot Plant for the remanufacturing and recycling of mechatronic components (automotive, large machinery, electronics, white

goods), has been designed and installed at STIIMA-CNR (January 2013). The pilot project was co-funded by Regione Lombardia with a

grant of 1.5 Million Euro.

Cell 1: Disassembly

Cell 2: ReworkingCell 3: Recycling

3 – Envisaged inter-regional nodes configurationLombardy

Politecnico di Milano has recently supported the developent of a new Interdepartmental Laboratory, that will be located at the Mechanical Engineering Department, called CIRC-eV, aiming at developing and testing new circular solutions for Li-Ion batteries re-use. 7

Departments are involved.

Smart I4.0 modular system for battery disassembly, reassemblyand mechanical pre-treatment for recycling.

Thermally controlled room, frequencyresponse analyzer, IES (ElectrochemicalImpedance Spectroscopy)

Battery testing, characterization, and residual life-time analysis.

Operation monitoring (disassembly, US welding, mechanical joining, cuttingand size reduction), operator supportsystem, thermal battery monitoringduring operations.


Spent Lamps

Fluorescent lamps powder

Rare earth oxalates

“The Vanguard De-and Remanufacturing pilotnetwork is a new way to share innovation.”

“Relight as a member of this pilot, aims atopening new markets by establishing asustainable cooperation within the pilot toattract new industrial users of Relighttechnologies and to pave the way for newrecycling services.”Bibiana Ferrari, CEO of Relight s.r.l.


ENERGYSPECTRUM

XSPECTRA® DETECTOR

ENERGYSPECTRUM

WATER

WATER+AMMONIA

“Xnext developed the most advanced real time material scanner that willrevolutionize the quality control testing for manufacturing and will make possibleto identify and separate the materials in circular economy applications. Inperspective, the 30% of Xnext sales 2020 budget will be generated by revenuesfrom circular economy applications”.

“The De-and Remanufacturing pilot will represent a fundamental installation forshow-casing the potentiality of our technology in an integrated pre-industrialenvironment, thus supporting Xnext in gaining market shares in many differentsectors”Bruno Garavelli, Founder of Xnext


Chemical ProcessesSmart DisassemblyManual Semi-automated

Inspection, Materials Analysis, Certification

Mechanical Processes

ICT tools & Simulation

Shopfloor

DIGITAL VIRTUAL

SMART

FITMAN DyVisual

Application MashupFITMAN Collab.

Asset Management

IoT Device IoT Device IoT Device IoT Device IoT Device

Big Data

Publish/SubscribeContext Broker

IoT DeviceManagement

IoT Broker IoT Discovery

FITMAN Dynamic CEP

Information Systems

Enterprise ApplicationsIoT & M2M Applications

Smart System

SecureGateway IoT Protoco Adapter(s)

IoT Data Handling

Remanufacturing Business Model, Reverse Logistic and LCA

308

681

2,476

4130

108

698130

1,955

49926

35

61

217

130 2,216

130130

13029

29

FROMTREATMENTCENTERSINTHEREGION…

…TODE-ANDRE-MANUFACTURINGPLANTSLOCALIZATIONANDASSIGNMENTOFFLOWS….

Lombardy Infrastructure: new infrastructure: 400m2 ca.; 12,5M€• Integration of advanced and innovative technologies and digital innovations (TRL7-8)• Modular and reconfigurable Pilot Plant for different use-case.• High degree of integration, automation and control.

ENERGYSPECTRUM

XSPECTRA® DETECTOR

ENERGYSPECTRUM

WATER

WATER+AMMONIA


EU Initiatives supporting the pilot


https://greenomed.interreg-med.eu/

@GREENOMED_EU GreenomedGreenomed

2 M € Project

Budget

1,7 M € ERDF

30 MONTHS

Project

Duration

Challenges

• Identification of common topics and backgrounds

• First step of identification of companies needs and proposals

• Cluster and RTO clustering of the topics to create a common background

• Cluster and RTO Create a value chain based on the proposed topics

• Funding issues

• Expert members on market analysis and business planning

• Developed a detailed business plan to ask for funding

• Use the opportunity of generated projects based on the topics raised in WG


“De- and Remanufacturing”

Pilot Network

4 pages

Pilot SummaryBusiness Model doc

63 pages

Investment Plan

35 pages

Region Technical contact Organization EmailLombardy Marcello Colledani Politecnico di Milano [email protected] Minna Lanz Tampere University of Technology [email protected] Luis Carneiro INESC Porto / PRODUTECH Cluster [email protected] Winifred Ijomah Scottish Institute for Remanufacture - Strathclyde [email protected]

Saxony Katja HaferburgFraunhofer Institute for Machine Tools and Forming Technology

[email protected]

Basque Country Ane Irazustabarrena Tecnalia [email protected] Joost Duflou Ku Leuven [email protected] Stéphane Neirynck CTP [email protected]

Thank you for your attention!

Golboo Pourabdollahian

CNR-STTIMA


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