BMW i4 eDrive40 battery recycling in Lyon, France
Lyon, France does not take whole packs. It receives black mass made from BMW i4 eDrive40 modules that failed grading, and turns it into battery-grade salts.
Pack value at 80% SOH
3,932 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 BMW i4 eDrive40 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 8 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 BMW i4 eDrive40 battery
The BMW i4 eDrive40 (2022) carries a 83.9 kWh NMC 811 Cylindrical 2170 pack with 8 modules at 398 V, weighing roughly 470 kg. High-nickel cylindrical cells with the strongest hydrometallurgical recovery credit per tonne of black mass.
| Service year | SOH | Grade | Value |
|---|---|---|---|
| Year 2 | 94.5% | A — BESS ready | USD 5,244 |
| Year 4 | 90.2% | A — BESS ready | USD 5,035 |
| Year 6 | 85.9% | A — BESS ready | USD 4,754 |
| Year 8 | 81.6% | B — Second life | USD 4,135 |
| Year 10 | 77.3% | B — Second life | USD 3,625 |
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 BMW i4 eDrive40 pack
83.9 kWh, 8 modules, about 470 kg — this is how the Lyon, France team plans the job.
Removal
Packs are dropped on a vehicle lift using the OEM procedure and a rated battery table, then isolated at the service disconnect.
Packaging
One pack per UN-rated pallet box, strapped and restrained, with terminals capped and coolant ports sealed.
Consolidation
Dealer and workshop returns are consolidated into full truckloads, typically eight or more packs per run.
Before the truck arrives
- Pull the service disconnect and record pack voltage
- Drain or cap coolant lines before lifting
- Photograph the pack casing and any impact damage
- Keep the VIN and pack serial together on the manifest
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
4.77 kg
nickel
30.82 kg
cobalt
3.82 kg
manganese
3.55 kg
copper
15.28 kg
aluminium
12.82 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.
BMW i4 eDrive40 in Lyon, France: common questions
Can I drop off a BMW i4 eDrive40 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 BMW i4 eDrive40 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 BMW i4 eDrive40 pack be prepared for pickup?
Pull the service disconnect and record pack voltage. Drain or cap coolant lines before lifting. Photograph the pack casing and any impact damage. Keep the VIN and pack serial together on the manifest.
Which rules apply to BMW i4 eDrive40 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
BMW i4 eDrive40 at other sites
Retiring BMW i4 eDrive40 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.