INNOVATORS DAY 10.09.2025
TECH METAL TRANSFORMATION CHALLENGE
DESIGN OFFICES BERLIN HUMBOLDTHAFEN | ALEXANDERUFER 3-7 | 10117 BERLIN
AGENDA
10:00 – 10:30 Arrival + Coffee
10:30 – 11:15 Tech Metal Transformation Challenge: Intro + Q&A
11:30 – 12:30 Matchmaking – Part 1 Individual SPRIND sessions
12:30 – 13:00 Lunch Break
13:00 – 14:00 Mentor/NSF/jury talks Individual SPRIND sessions
14:00 – 15:00 Matchmaking – Part 2 Individual SPRIND sessions
Closing Final tips and advice from SPRIND Team
WHAT YOU SHOULD GET OUT OF TODAY
✓ Hear first-hand from the SPRIND team about design and vision of the challenge.
✓ Ask us questions about the challenge and get 15 minutes of unfettered access with the team for a private conversation, where you can preview your idea.
✓ Build your network. You might have part of the solution but are looking for others to create A team or join someone else's team.
✓ Gain insight into the complex e-waste recycling value chain and learn about today's challenges from senior industry experts.
✓ Meet our partners at the U.S. National Science Foundation, who will be developing the aligned us version of this challenge.
TECH METAL TRANSFORMATION CHALLENGE
OVERVIEW
THE SPRIND SPIRIT
WE EMBRACE UNCONVENTIONAL, CREATIVE, INTERDISCIPLINARY APPROACHES THAT CHALLENGE THE STATUS QUO.
WE EMPOWER RISK TAKERS, CELEBRATE FAILURE, AND SEEK OPENMINDED INDIVIDUALS, WHO ARE MORE PRONE TO SERENDIPITOUS DISCOVERY.
EVERYTHING MENTIONED IN THIS BRIEFING IS OUTLINED IN THE APPLICATION MATERIAL
VISION
DEVELOP AN END-TO-END PROCESS IN WHICH RECOVERED METALS CAN BE DIRECTLY REUSED AS FUNCTIONAL MATERIALS WITH A LIFE-AFTER-NEXT IN MIND.
ACHIEVE PILOT PLANTS WITH A TECHNOLOGY READINESS LEVEL OF 6 TO 7 WITHIN THREE YEARS.
ALL METALS ARE UP FOR THE TAKING
SMARTPHONES USE 69 ELEMENTSLESS THAN 25% RECYCLED
CRITICAL METALS ARE OFTEN LOST NO VIABLE BUSINESS CASE FOR LOWVALUE, HIGHLY DISPERSED METALS
THE STARTING POINT: SHREDDED MOBILE PHONE
CIRCUIT BOARDS AND DISPLAYS
UTILIZE AN INTERDISCIPLINARY APPROACH
UTILIZE BIOLOGICAL, CHEMICAL AND PHYSICAL-MECHANICAL APPROACHES AND BUILD A MODULAR SYSTEM TO GAIN ACCESS OF THESE CRITICAL METALS.
CHANGE THE WAY WE PROCESS METALS FROM WASTE
REDUCE ENERGY
CONSUMPTION, REDUCE WASTE STREAMS, LIMIT THE USE OF TOXIC INDUSTRIAL CHEMICALS, REFINE RESOURCE INTENSE PROCESSES
Source: Ambaye, T.G., Vaccari, M., Castro, F.D. et al. (2020).
THINK BEYOND JUST RECOVERY
Produce new, functional materials with targeted industrial applicability
• High-entropy alloys with a better strength-to-weight ratio, a higher degree of breaking and tensile strength, as well as corrosion and oxidation resistance
• Bio-based nanoparticles with tailored shape & size for diverse industries
SELECTION CRITERIA
• The processes are to be optimized in such a way that metal losses through dissipation are avoided, energy consumption is significantly reduced and the resulting products are optimized in terms of their functionality in line with market requirements.
• Projects are developed from the laboratory stage (TRL 2/3) to prototypes in a real operating environment (TRL 7).
• If you have not created or have an existing company in year two, your chances of moving to Stage 3 are limited.
PROOF OF CONCEPT
FUNCTIONAL EXTENSION
DEMONSTRATION OF THE SOLUTION
NUMBER OF TEAMS
FURTHER DEVELOPMENT
3 STAGES IN 3 YEARS
STAGE 1 - LAB
Demonstrate high recovery rates on
standard e
Validate the process for at least one market
STAGE 2- PILOT
Integrate biological, chemical & mechanical steps
STAGE 3 – REAL-WORLD
STAGE 1 FROM TRL2/3 TO 4
STAGE 1
• Identify the key fractions or target metals suitable for recovery and functional transformation from shredded mobile phone circuit boards and displays.
• Demonstrate a process route that produces at least one functional metal product with real application potential.
• Validate important process steps on a laboratory scale: carry out small-scale tests with the process steps and record material balances and energy input per step.
STAGE 1
• Use the measured recycling yields as well as the officially provided supply risk and economic importance values to calculate an initial critical raw materials score.
• HAZOP analysis of the process: implement a basic safety concept for the handling of byproducts such as toxic gases and brominated flame retardants.
• LCA preview: indicate values for energy use and main reagents and complete an assessment of how these values can be improved through scaling or optimization.
• Provide analytical proof that the recovered material meets the purity or functionality requirements.
STAGE 2 FROM TRL4 TO TRL5/6
OPTIMIZE, INTEGRATE AND MAKE BIOLOGICAL, CHEMICAL, MECHANICAL PROCESSES MORE FLEXIBLE
STAGE 2
• Reduce metal dissipation and energy requirements to a minimum.
• The metal or mineral products obtained are to be optimized in terms of their functionality.
• At least one end-of-life product is to be completely recycled.
• Complete a comprehensive techno-economic analysis and a life cycle analysis.
STAGE 3 FROM TRL5/6 TO TRL7
FIRST DEMONSTRATOR IN THE FORM OF A SCALABLE AND FUNCTIONAL END-TO-END PROTOTYPE
STAGE 3
• Demonstrate in a real operating environment how the complete metal inventory of at least two significantly different end-of-life products can be processed into functional metal or mineral products.
• The functional metal or mineral products obtained must be suitable for direct use by customers and demonstrated for use in proof-of-concept manufacturing.
• The process must include a complete life cycle.
• This demonstrator must show how it can be integrated into existing industrial recycling processes or disrupt them in terms of material recovery and economic viability.
IMPORTANT DATES
THE APPLICATION PERIOD RUNS UNTIL NOVEMBER 7, 2025 (18:00 CET).
INVITATIONS TO PITCH IN PERSON TO SPRIND WILL BE 4/5 DECEMBER
THE CHALLENGE STARTS ON THE DAY OF THE JURY DECISION (DECEMBER 5)
IT IS PUBLISHED AND AVAILABLE WITH THE APPLICATION DOCUMENTS THE CONTRACT IS NON-NEGOTIABLE
WHAT WE ARE OFFERING
FOR STAGE 1, 8 TEAMS MAY RECEIVE UP TO EUR 1,500,000 (PLUS VAT) EACH.
UP TO SIX TEAMS WILL ADVANCE TO STAGE 2, WITH FUNDING OF UP TO EUR 2,000,000 (PLUS VAT) PER TEAM.
FOR UP TO FOUR TEAMS MOVING INTO STAGE 3, SPRIND WILL PROVIDE UP TO EUR 2,500,000 (PLUS VAT).
WITH FUNDING BASED ON EACH TEAM’S PROJECTED COSTS
WEEEcycling
- opportunities & challenges for CRM recovery from complex (electronic) products
Dr. Christian Hagelüken
SPRIND Innovators Day
Berlin, 10.9.2025
▪ Biggest challenge in recycling of electronic products?
►Their proper collection at EoL
▪ Challenge No. 2?
► Channelling collected EoL products into best performing processes
▪ Challenge No. 3? (overarching)
► Making it all economically viable without negative side effects
▪ Challenge No. 4?
►High quality recycling technology coping with product complexity
→ Effective recycling technology is key for CRM recovery – but it‘s useless when not properly embedded into the overarching system
Effective collection crucial for economic viability
Challenges: Low value of single unit,
complex waste mixes & product compositions
• Metal value of 1 smart phone: 2 €*
(at current record prices for Au & Ag)
• Net value of 5 t of phones at gate of Umicore recycling plant: ≤ 90,000 €
• Metal value of ~2 B mobile phones sold globally annually: 4 B €
E-scrap / mobile phones, a complex mix …
▪ Ag, Au, Pd… (precious metals)
▪ Cu, Al, Ni, Sn, Fe, Bi, Sb, In… (base & special metals)
▪ Hg, Be, Pb, Cd, As, …(hazardous substances)
▪ Halogens (Br, F, Cl...)
▪ Plastics & other organic materials
▪ Glass, ceramics, wood, …
Environmental risk in case of landfill/bad recycling
Important source for raw materials (incl. CRM)
Challenge: Recycling of complex multi-material assemblies*
How to recycle responsibly?
→ cope with hazards while recovering value
High quality recycling
= economically viable recovery
• of various relevant contained materials,
• with high yields,
• in marketable quality,
• and meeting high environmental**- & social standards.
** incl. energy & CO2-balance
* e.g. electronics
Umicore
Multi metal recycling requires optimised chains
Approach & challenges in mechanical pre-processing
Separation
efficiency is decisive factor for overall metal yields
source: Reuter/ Van Schaik, 2010
Co-Ni-Cu-Li recycling from Li-Ion batteries
Multi-Metals Refining @ Umicore Hoboken
process based on Cu/Pb/Ni metallurgy, input capacity up to 500,000 t/a
Au, Ag, Pt, Pd, Rh, Ru, Ir, Cu, Pb, Ni, Sn, Bi, Se, Te, In, Sb, As
Recyclables: catalysts, circuit boards, …
Industrial by-products: smelter intermediates, slags, dusts, bottom ashes, …
Collector metals
17 different metals
• Highly flexible, energy efficient & robust process
• High performance due to optimised input mix
• In addition, dedicated process for battery recycling, recovering Co, Ni, Li, Cu
© Umicore © Umicore
Christian Hagelüken, SPRIND Innovators Day Berlin, 10.9.25
Metallurgy for multi metal recycling
Opportunities, challenges, limits
Recycling prerequisite: channelling of the relevant material fractions to such plants!
• High recycling yields for (chemically noble) metals that fit metallurgically/thermodynamically – even as trace elements!
• The value of precious metals & Cu enables co-recovery of (many) other metals – if state-of-the-art facilities are used.
• Success factors: Economies of scale, technical infrastructure, metallurgical skills.
• Ignoble metals in input-Mix (Al, Fe, Ga, Ge, Ta, REE, Li, …) are lost as oxides to the slag (→ high dilution)
neither economical nor environmentally beneficial to recover these from the cold final slag.
• To recover these metals, dedicated metallurgical processes are needed (and available)
such target metals need to be separated & concentrated beforehand in pre-processing
→ Li-Ion batteries: Co, Ni, Li, Cu
→ Al; Steel; REE-magnets; Ge-residues...
• Need to mitigate CO2-emissions from fuel, energy & organic input.
• Slag discharge is crucial, need for reliable slag utilisation options.
• Metallurgical sites are the backbone of an EU circular economy.
Umicore Hoboken, Belgium
© Umicore
Some principal optimisation approaches for CRM recycling from complex multi-metal mixes
(technical/organisational)
➢ Optimisation of interfaces for processing/pre-treatment:
• Pre-sorting of products („separate smartphones from electric toothbrushes“)
• Pre-separation of relevant components (batteries, magnets, LCDs, Al-heat sinks/housings, Fe-frames, …)
• not useful: separation of smallest components (e.g. Ta-capacitors) from complex assemblies,
usually leads to losses of other valuable materials (e.g.Ag, Pd), high costs
➢ More selective collection: collection groups more strongly orientated towards recycling requirements
➢ Better transparency of real material flows at EoL
➢ Improved product design: modular structure, accessibility of raw material-relevant components (see above)
➢ New metallurgical processes:
• Separation of „ignoble“ metals via the gas phase upstream/in the smelter (“fuming”)
• Separation from the liquid slag
Product passports, process-digitalisation along recycling chain, AI, optical recognition, new online (analytical) tools, etc. are offering new opportunities to improve CRM recovery
►Make sure: output materials to be suitable as reliable input for new products
Recycling economics: What’s the right price for “waste”?
Waste price recoverable material value
material content x yield x price product composition & market trends (pollutants can have negative value)
• Technical performance
• Process chain efficiency
• Factor costs (labour, energy, capital)
• Available volumes/economies of scale
• EHS-performance (incl. reporting & hazardous emissions control)
• Shipping costs (incl. taxes, customs)
• Administrative costs (incl. time delays)
Impacted by:
Recycling industry Legislation & enforcement Trade regulations
The lack of level playing field for EHS-compliant high-quality recyclers hampers the circular economy recycling chain costs recycling fee* = - +
*legislation / business model to cover externalised costs
C. Hagelüken, C. Meskers (2023): Economic aspects of metal recycling, in: Handbook of Recycling (2nd ed.), Elsevier, 627-644
4. Smart (political) framework conditions, subsidies & incentives enable the recycling of all (critical) metals
2nd law of the recycling economy: All metals can be recycled in principlebut not from every combination of materials (entropy problem)
• Challenge of complex products & multi-material mixtures: requires prioritisation → what can be ‘sacrificed’ to enable the extraction of a target metal?
• Consider thermodynamic limits of metallurgy (e.g. chemically noble vs ignoble metals); compatible and incompatible trace elements.
• Importance of product design and mechanical processing technology. → can incompatible components/material mixes be separated before metallurgy and fed into suitable special processes (e.g. magnets, batteries)?
• Limits of R&D funding: 100% recycling is impossible.
Regulation, incentives and R&D funding are important, but they face thermodynamic/physical limits.
Concluding – Overall recycling success factors
Prerequisites:
1. Technical recyclability & generation of marketable output as basic requirement
2. Accessibility of relevant components → product design
3. Economic viability intrinsically or externally created
4. Comprehensive collection
5. Transparency on real flows of EoL products
6. Use of best performing recycling infrastructure
7. Optimal technical-organisational set-up of chain
Complex products require a systemic optimisation & interdisciplinary approaches (product development, process engineering, metallurgy, ecology, social & economic sciences)
Sustainable metals management only works in a systemic approach
contact: christian.hagelueken@t-online.de
Publications: www.researchgate.net/profile/Christian_Hagelueken/contributions
C. Hagelüken, D. Goldmann (2022): Recycling and circular economy - towards a closed loop for metals in emerging clean technologies, Mineral Economics, https://rdcu.be/cNsl7
UBA Ressourcenkommission (2023): Opportunities & limits of recycling in the context of the Circular Economy – frame conditions, requirements, and recommendations for action.
C. Hagelüken, C. Meskers (2023): Economic aspects of metal recycling, in: Handbook of Recycling (2nd ed.), Elsevier, 627-644
© Umicore
• CE is more than recycling - also optimise use & service life (incl. repair).
But at some point, high-quality recycling is required to physically close material cycles!
• CE is essential for a sustainable supply of raw materials in Europe.
• ‘Good’ recycling is more expensive than poor recycling Regulation & standards are important!
• Recycling (only) ends with the production of marketable material (for the manufacture of new products).
• The more complex the material composite & the greater the variety of materials, the more difficult it is to recycle many ingredients.. Take priorities: recovery of recyclable materials and avoidance of pollutants.
• High-quality industrial recycling processes already exist for complex products (electrical and electronic products, catalytic converters, EV batteries, etc.). Make sure that they are used!
• No recycling without collection! Create more collection incentives and better transparency about real material flows at the end of a product's life (→ potential key role for product passports).
• Innovative business models for CRM-relevant consumer goods are decisive. New forms of collaboration (‘roundstream’) & product service models/leasing as game changers.
• Focus: CE strategies for ‘green’ products, as they increase demand for (critical) raw materials and must be sustainable by definition. E-mobility is an ideal test case for CE.
Christian Hagelüken, SPRIND Innovators Day Berlin, 10.9.25
EU Circular Economy*
“
… where the value of products, materials and resources is maintained in the economy for as long as possible, and the generation of waste minimized… to develop a low carbon, resource efficient and competitive economy”
EC Communication Dec. 2015 “Closing the loop – An EU action plan for the Circular Economy”
Metals are the ideal candidate: “eternally” recyclable, no downcycling, no material quality issues…
CE = much more than recycling (use efficiency, repair, reuse, …) but finally raw material loops need to be closed physically!
➢ Loop is only closed if recyclates are reused for production of new products (replacing primary metals).
➢ Current waste legislation misses this physical aspect. Reported recycling rates cannot be taken as suitable indicators for CE.
* Meaning going beyond the traditional German expression „Kreislaufwirtschaft“
Christian Hagelüken, SPRIND Innovators Day Berlin, 10.9.25
Factors impacting the economic viability of recycling
Macro-economic/societal level
• Resource conservation
• Supply security
• Responsible sourcing
• CO2 footprint
• Environmental protection
Micro-economic level
• Product type & composition
• Market prices of metals
• Recycling performance
• Economies of Scale
Addressed in CRM-Act, NKWS & other policy initiatives but so far without a ‚price tag‘
Consider
• societal benefits
• externalised costs for society
Indirect impacts:
• Collection infrastructure
• External collection incentives (e.g. leasing, deposits, …)
• Legislation / monitoring / enforcement
• Business model for product (B2C, B2B)
• Stakeholder behaviour & motivation (Consumers, OEMs/EPR culture, distributors, recyclers)
Christian Hagelüken, SPRIND Innovators Day Berlin, 10.9.25
Development of precious metals contents in electronics (Ø-values)
Metal price volatility: significant impact on recycling value
Price development Au, Ag, Pd & Pt 1988-2025/05
AurubisAG MetalsforProgress
SPRINDTech-MetalTransformation
Innovators’Day
TorbenEDENS,Berlin,10September2025
Copper-thematerialformodernlife recyclingisincreasing,butnotenoughtocoverallcopperdemand
Characteristics
»Electricmotors
»Cablesandwires
»Microchips
»Airconditioners
»Heatexchanger
»Kitchenappliances
»Sanitaryinstallation
»Piping
»Roofsandfacades
»Coins Final
»Transformers
»Brakepads
Aurubis
TypicalLifespansofCopperProducts
BuildingandConstruction:Copperpipes,roofing,cladding:~50–100years
Theseproductsareoftenembeddedininfrastructureandhavelongservicelives duetocopper’scorrosionresistanceanddurability.
ElectricalApplications:Wiringinbuildings:~30–50years, Consumerelectronics:~5–10years
Electricalcomponentstendtohaveshorterlifespansdueto rapidtechnologicalturnover.
TransportSector:Copperinvehicles(e.g.,wiringharnesses):~10–20years
IndustrialEquipment:Machineryandheavy-dutyapplications:~20–40years
Oftenreusedorrefurbished,extendingeffectivelife.
OtherUses(e.g.,coins,cookware,art):Highlyvariable,oftendecadesoreven centuriesinsomecases.
Therecycledcoppersupplyisdelayed,creatingatimelagbetweenproductionandrecovery.
Recyclingmarkettrends
Strongglobalmacrotrendsdrivegrowthinrecyclingmarkets SPRINDTech-MetalTransformation-Innovators'Day
Multipolarbusiness world
Morecomplex materials
Increasingrecycling efforts
Localhandlingof recyclingmaterials
Growthinemergingcountrieswilloutpace Westerncountries
Risingnumberofelementsanddecreasing metalcontentinprimary&recyclingraw materials
Stricterlegislationandincreasingconsumer awarenessregardingsustainability
Developingcountriesarereducing orbanningimportsofwaste materialsfromtheWesternworld
Aurubis
GlobalCopperDemand
Source:WoodMackenzie-GlobalcopperstrategicplanningoutlookQ22025
PrimaryvsSecondaryRecycling?
Copperis100%recyclablewithoutlossof properties:
32%ofglobalcopperdemandismetthrough recycling.(Aurubiscathodescontain45% recycledcopper) Two-thirdsofallcoppereverminedisstillin usetoday.
Thishighrecyclabilitymeansthatcopperoften re-enterstheproductioncyclemultipletimes, effectivelyextendingitsfunctional lifetimeacrossgenerationsofproducts.
TheInternationalCopperAssociation
Howiscopperproduced?
Recyclingprocess
SPRINDTech-MetalTransformation-Innovators'Day
Aurubis:weareexpertsformetals.
Successfulin
20countrieson
3continents
>7,000x passionand engagement
159years experienceinthe productionofnonferrousmetals
about1milliont
20 Oneofthe worldwideleading companiesin copperrecycling ofrecyclingmaterials isprocessedbyAurubis onayearlybasis
SPRINDTech-MetalTransformation-Innovators'Day
differentmetals arerecoveredby Aurubis
Aurubis
OurstrategybuildsonthesoundmissionofAurubisandcoversall relevantaspectstodrivesustainablegrowth
Secure CoreBusiness Strengthen CoreBusiness Pursue GrowthOptions
IndustryLeadershipinSustainability
EnablersDigitalization,automation,and “PlantoftheFuture”
Strategicresourcemanagement,talentand personneldevelopment
Itisourmissiontoresponsiblytransformrawmaterials intometalsforaninnovativeandsustainableworld.
SPRINDTech-MetalTransformation-Innovators'Day
Aurubis
Aurubisproductionsites
HeadquartersPrimaryCopperRecycling/PreciousMetals
CopperProducts
Aurubis
SPRINDTech-MetalTransformation-Innovators'Day
Lünen
Pirdop
Olen
Beerse
Berango
Pirdop(BG)
Berango(ES)
Olen (BE)
Beerse (BE) Lünen(DE)
Hamburg (DE)
RecyclingNetwork
Richmond–SecondaryCopperSmelter
RecyclingdedicatedtoPrintedCardboards
Off-gascleaning
Sampling, Blending
PbSn-alloyfurnace
PbSn-alloyingots
Aurubis
SlagholdingfurnaceGranulatedslag
Blackcopperingots
Lünen–SecondaryCopperSmelter
Recyclingdedicatedforcopperscrapswithoutsulphur
Abgasreinigung
Schlämme Rückstände
Probenahme, Materialvorbereitung
KRS
KayserRecyclingSystem
E-Schrott Schwarzkupfer80%
TSL
ZinkoxidTBRC
Eisensilikatsand
Altkupfer
Konverterkupfer95%
Abgasreinigung
Blei-ZinnLegierung
Anodenofen
Anodengießanlage Anode KupferelektrolyseEdelmetallgewinnung Kathode Nickelsulfat Kupfersulfat Anodenschlamm
Aurubis
Hamburg–PrimaryCopperSmelter
dedicatedtoCu-sulphidesandScraps
Sulfuricacidplant
Wasch-&Kühlanlage Washing&Coolingsection Kontaktanlage Contactplant
E-scrap
Hamburg–SecondaryLeadandPM-Smelter dedicatedtoCu-Pb-separationandPreciousMetalExtraction
Aurubis
ElectronicWasteRecyclingChallenges
E-wastecontainsover1,000differentchemicals,includingheavymetals(lead,mercury, cadmium),polychlorinatedbiphenyls(PCBs),brominatedflameretardants,andplastics.Improper handlingreleasestoxicsubstances.
•Collection,sortingandsamplingareimportantpartsoftherecyclingprocess:
•Creatingmanyfractionsspreadsvaluablemetalsandreducesrecoveryratesbecauseselectivityisnotunlimited.
•Impropersamplingjeopardizesbusiness.
•Extractivecopperpyrometallurgyoffershighrecoveryratesformanymetals(Ag,Au,Cu,Ni,Pb,Pd,Pt, Se,Te,Sn,Zn)andbromides.
•Theplasticsareburned,producingCO2andheat.
•Thefiberglassisslagged.
•Unfortunately,therareearthelementsarelostintheslag.
•Hydrometallurgyisoftenveryselective,butextractingonlyonemetalandleavingtheresidueforfurther (pyro)processingisnotattractive.
Recyclingisacomplexprocessthatneedsaholisticviewconcerningenvironment(air,water), legistaltion,technologyandeconomics.
SPRINDTech-MetalTransformation-Innovators'Day
Aurubis
AurubisAG MetalsforProgress
SPRINDTech-MetalTransformation
Innovators’Day
TorbenEDENS,Berlin,10September2025
