Bajaj Chetak 3501 battery recycling in Lyon, France
Lyon, France 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
23,000 TPA
Hydrometallurgical Refinery
Cities served
3
From Lyon, France
Where a Bajaj Chetak 3501 pack goes from Lyon, France
- 1
Collected via Dubai, UAE
Whole packs enter the network at Dubai — Jebel Ali Logistics Yard, 5,003 km away, where they are weighed and de-energised.
- 2
Graded at Stuttgart, Germany
Modules travel 469 km to Stuttgart — Baden-Wurttemberg Grading Works for capacity, resistance and impedance testing across all 2 modules.
- 3
Second life at Zwickau, Saxony
At 80% SOH about 47% of the pack qualifies for reuse and goes to Zwickau — Saxony Second-Life Works (790 km). Good — grade-A modules above 80% SOH qualify for commercial-scale BESS strings.
- 4
Refining at Lyon, France
Black mass from failed modules is leached and refined here into battery-grade nickel, cobalt and lithium salts.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Dubai — Jebel Ali Logistics Yard | 5,003 km |
| Nearest grading bench | Stuttgart — Baden-Wurttemberg Grading Works | 469 km |
| Nearest second-life works | Zwickau — Saxony Second-Life Works | 790 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 Lyon, France 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
Lyon, France site notes
- Only black mass and scrap are accepted.
- Cross-border shipments need prior documentation.
- Bulk bags must be sealed and labelled.
- Settlement follows assay 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 France
EU Battery Regulation (EU) 2023/1542 and the French EPR (REP) system
Regulator: Ministry for Ecological Transition, with ADEME overseeing producer responsibility schemes
The refinery operates under French permitting for classified installations (ICPE) and the EU Battery Regulation (EU) 2023/1542. Waste shipments follow the EU Waste Shipment Regulation.
Bajaj Chetak 3501 in Lyon, France: common questions
Can I drop off a Bajaj Chetak 3501 battery at Lyon, France?
Lyon, France is a hydrometallurgical refinery and does not accept whole packs from customers. Book a collection and the pack enters the network at Dubai, UAE, 5,003 km away.
What happens to Bajaj Chetak 3501 modules after Lyon, France?
Collected via Dubai, UAE, then Graded at Stuttgart, Germany, then Second life at Zwickau, Saxony, then Refining at Lyon, France. 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 France?
EU Battery Regulation (EU) 2023/1542 and the French EPR (REP) system, overseen by Ministry for Ecological Transition, with ADEME overseeing producer responsibility schemes. Road transport follows ADR, and cross-border shipments follow the EU Waste Shipment Regulation.
Cities collected by Lyon, France
Bajaj Chetak 3501 at other sites
Other two-wheeler packs at Lyon, France
Retiring Bajaj Chetak 3501 packs near Lyon, France?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.