Bajaj Chetak 3501 battery recycling in Haldia, West Bengal
Haldia, West Bengal does not take whole packs. It receives black mass made from Bajaj Chetak 3501 modules that failed grading, and turns it into battery-grade salts.
Pack value at 80% SOH
164 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
15,000 TPA
Hydrometallurgical Refinery
Cities served
0
From Haldia, West Bengal
Where a Bajaj Chetak 3501 pack goes from Haldia, West Bengal
- 1
Collected via Khordha, Odisha
Whole packs enter the network at Bhubaneswar — Khordha Collection Yard, 331 km away, where they are weighed and de-energised.
- 2
Graded at Pithampur, Madhya Pradesh
Modules travel 1,279 km to Indore — Pithampur Grading Plant for capacity, resistance and impedance testing across all 2 modules.
- 3
Second life at Butibori, Maharashtra
At 80% SOH about 47% of the pack qualifies for reuse and goes to Nagpur — Butibori Second-Life Works (956 km). Good — grade-A modules above 80% SOH qualify for commercial-scale BESS strings.
- 4
Refining at Haldia, West Bengal
Black mass from failed modules is leached and refined here into battery-grade nickel, cobalt and lithium salts.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Bhubaneswar — Khordha Collection Yard | 331 km |
| Nearest grading bench | Indore — Pithampur Grading Plant | 1,279 km |
| Nearest second-life works | Nagpur — Butibori Second-Life Works | 956 km |
Faster option
Inside the Bajaj Chetak 3501 battery
The Bajaj Chetak 3501 (2024) carries a 3.5 kWh NMC 811 Cylindrical 2170 pack with 2 modules at 50 V, weighing roughly 20 kg. High-nickel cylindrical cells with the strongest hydrometallurgical recovery credit per tonne of black mass.
| Service year | SOH | Grade | Value |
|---|---|---|---|
| Year 2 | 95.4% | A — BESS ready | USD 221 |
| Year 4 | 91.1% | A — BESS ready | USD 212 |
| Year 6 | 86.8% | A — BESS ready | USD 203 |
| Year 8 | 82.5% | B — Second life | USD 178 |
| Year 10 | 78.2% | B — Second life | USD 155 |
What the chemistry means here
How it ages
NMC 811 loses capacity through a mix of SEI growth, cathode surface reconstruction and micro-cracking of nickel-rich particles. Resistance climbs faster than in LFP, which matters as much as capacity for second-life duty.
Thermal behaviour
High-nickel NMC cathodes release oxygen as they decompose, so once runaway starts it is fast and energetic. Cylindrical 2170 cells vent through a designed rupture point, which helps, but cell-to-cell propagation inside a tightly packed module is the main hazard.
Handling NMC 811 (2170)
Collecting a Bajaj Chetak 3501 pack
3.5 kWh, 2 modules, about 20 kg — this is how the Haldia, West Bengal team plans the job.
Removal
Removable packs are unclipped by hand; fixed packs are removed at the dealer bench with the frame supported.
Packaging
Packs travel in UN-approved steel or plastic cages with non-conductive dividers, typically dozens per cage.
Consolidation
Dealer and swap-station returns are aggregated at a single point so one collection clears many units.
Before the truck arrives
- Tape terminals and connectors on every pack
- Separate swollen or dropped packs into their own container
- Record serials in a single list per cage
- Store below 30% charge away from charging racks
Haldia, West Bengal site notes
- Whole packs are not accepted; send them to a collection or grading site first.
- Black mass must arrive in sealed, labelled bulk bags with declared chemistry.
- Port-linked deliveries need documents lodged before arrival.
- Settlement is based on sampling and assay carried out at intake.
What this pack yields
lithium
0.2 kg
nickel
1.29 kg
cobalt
0.16 kg
manganese
0.15 kg
copper
0.64 kg
aluminium
0.53 kg
Refining-route estimate at 80% SOH. Measured module health on the bench sets the final split.
Rules in India
Battery Waste Management Rules 2022 (BWMR)
Regulator: Central Pollution Control Board (CPCB) and State Pollution Control Boards
The works operates under West Bengal Pollution Control Board consent, with conditions on effluent treatment, air emissions and hazardous chemical storage. As a registered recycler it generates recovery evidence under the Battery Waste Management Rules 2022, and port shipments follow customs and applicable waste-shipment controls.
Bajaj Chetak 3501 in Haldia, West Bengal: common questions
Can I drop off a Bajaj Chetak 3501 battery at Haldia, West Bengal?
Haldia, West Bengal is a hydrometallurgical refinery and does not accept whole packs from customers. Book a collection and the pack enters the network at Khordha, Odisha, 331 km away.
What happens to Bajaj Chetak 3501 modules after Haldia, West Bengal?
Collected via Khordha, Odisha, then Graded at Pithampur, Madhya Pradesh, then Second life at Butibori, Maharashtra, then Refining at Haldia, West Bengal. At 80% SOH roughly 47% of the pack goes to second life and the rest is refined.
How should a Bajaj Chetak 3501 pack be prepared for pickup?
Tape terminals and connectors on every pack. Separate swollen or dropped packs into their own container. Record serials in a single list per cage. Store below 30% charge away from charging racks.
Which rules apply to Bajaj Chetak 3501 recycling in India?
Battery Waste Management Rules 2022 (BWMR), overseen by Central Pollution Control Board (CPCB) and State Pollution Control Boards. Retired packs move as hazardous goods by road under central motor vehicle rules, and export needs Basel-compliant permissions.
Bajaj Chetak 3501 at other sites
Other two-wheeler packs at Haldia, West Bengal
Retiring Bajaj Chetak 3501 packs near Haldia, West Bengal?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.