Zero Emission electric Vehicles enabled by haRmonised circulArity

Electric vehicles (EVs) are expected to contribute to 75% of new cars registered in Europe by 2030, backed by major markets’ internal combustion car phase-out regulations. At the same time, the manufacturing of EVs produces 80% higher CO2e emission compared to ICE cars. 

ZEvRA will enable the collaboration of five big OEMs, supported by top European universities and key players from all facets of the value chain (and three 2ZERO partnership members) and will demonstrate a harmonized circularity methodology that allows for interchangeability and replicability throughout Europe. The methodology and manufacturing technologies will be supported by digital tools and validated on a full circular car, integrating 8 prototype components covering 84% of the total automotive material mix. ZEvRA’s innovations aim to improve zero emission approaches in the life cycle and value chain of at least 59% of European EVs by 2035.

ZEvRA's main objective is to improve the circularity of light-duty EVs throughout their entire value chain, from materials supply and manufacturing to end-of-life (EoL) processes, which aligns with the European Union's goal of achieving zero CO2e emissions by 2035, particularly in the EV value chain. To do so, ZEvRA will develop a Design for Circularity (DfC) methodology and a holistic circularity assessment aimed at improving the production of electric vehicles (EVs) based on the 9Rs. This methodology will be validated by developing zero emission solutions for the most important automotive materials, covering > 84% material mix: steel, three versions of aluminium (wrought, casting, and foam), thermoplastics composites (long and continuous fibre-reinforced), unfiled/short fibre plastics, glass, tyres and Rare Earth Elements (REE). The Škoda Enyaq will be used as a baseline for the development of new technologies in this project.

These solutions will be supported by a set of digital tools to support the manufacturing of the use cases, the assessment of circularity, traceability, and the virtual integration of components into a full replicable vehicle. To maximise the outreach of our methodology and zero emission solutions, ZEvRA will develop a dedicated training & upskilling programme for the automotive workforce and academia, together with activities aimed at increasing awareness & acceptability of the proposed zero emission solutions. Lastly, circular business models targeting EoL and logistics aimed at improving the economic feasibility of circularity in EVs are advanced. 

RISE role in the project

ZEvRA workplan is organised in seven work packages (WPs). Besides supporting the partners in the different WPs, RISE is leading the WP2, Digital tools. The WP2 focuses on the development of various simulation and modelling techniques for predicting the properties and performance of materials and components used in 3 of the use cases – prototypes (WP4). Furthermore, WP2 will automate the systematization of LCT assessment of R9 strategies defined in WP1 (Circular economy methodology), and will also develop a DPP specific to automotive components.

Within the WP2, RISE will be developing models for creating digital twins of recycled composite materials with both long and short fibre composites. RISE will also be investigating the potential to simulate crystallinity in the filled and unfilled plastics used in the different demonstrator cases.