COMPANY NAME GaltTec
COUNTRY Estonia
SECTOR Renewable Energy, Aerospace & Defense
CIRCULAR BUSINESS MODEL Recovery and Recycling
CHALLENGE
GaltTec develops solid oxide fuel cells using proprietary ceramic microtubes. Their synthesis relies on alcohol-based solvents that were previously used once and sent for external hazardous waste treatment. This increased raw material consumption, disposal requirements, and production costs.
As the company prepared to scale manufacturing, it needed a practical way to recover and reuse these solvents without disrupting synthesis. The Material Recycle project addressed this challenge by developing an internal recovery route targeting at least 80% solvent recovery.
SOLUTION
With Up2Circ support, GaltTec developed and pilot-tested a solvent recovery process based on fractional distillation. The project combined waste-stream mapping, process design, safety assessment, operating procedures, and quality checks, using in-house expertise and laboratory equipment.
Recovered propanol-rich solvent was returned to synthesis and tested over three reuse cycles, with no systematic negative effect observed on synthesis or tube formation. Alongside solvent recovery, the team screened rejected ceramic material for potential reuse, identifying promising routes for extrusion and first heat-treatment waste.
CIRCULAR ECONOMY STRATEGIES/BUSINESS MODEL IMPLEMENTED
- Solvent recovery: Solvent previously treated as waste is collected, separated and returned to subsequent synthesis batches, retaining its value within the manufacturing process.
- Controlled reuse: Batch records, recovery-yield tracking, and quality checks provide a basis for controlled reuse as production grows.
- Material screening: Solid-waste screening identified opportunities to recover ceramic rejects for further evaluation in cell-making materials.
IMPACT
- Environmental impact: The pilot recovered 2.71 kg from 3.31 kg of processed solvent, achieving 81.8% recovery and exceeding the 80% target. Three reuse cycles maintained recovery yields above 80%. The lifecycle comparison estimated a 69% reduction in greenhouse gas emissions, from 9.9 to approximately 3.1 kg CO₂e per kg of main solvent. Recovery energy was estimated at approximately 0.67 kWh per liter, below the 1.2 kWh/L target.
- Economic impact: The project’s calculated cost comparison indicated savings of approximately €31 per liter of recycled solvent. Using existing laboratory equipment and internal expertise also reduced the need for external subcontracting, supporting an SME-appropriate approach.
- Social impact: GaltTec strengthened its team’s skills in circular process design, safe solvent handling, quality monitoring and data-based decision-making, embedding circular thinking into manufacturing development.
KEY TAKEAWAY
Material Recycle demonstrates that an SME can turn a manufacturing waste stream into a useful internal resource through practical process engineering and pilot testing. GaltTec exceeded its solvent recovery target and demonstrated repeated reuse, with promising environmental and economic benefits. The next step is routine implementation: reducing average water content from 2.2% to the 1% target, confirming solvent purity, and improving process control.