BMW i4 eDrive40 battery recycling in Zwickau, Saxony
Zwickau, Saxony receives graded BMW i4 eDrive40 modules that passed as grade A or B and rebuilds them into warrantied stationary storage.
Pack value at 80% SOH
3,932 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
20,000 TPA
Second-Life BESS Works
Cities served
0
From Zwickau, Saxony
Where a BMW i4 eDrive40 pack goes from Zwickau, Saxony
- 1
Collected via Dubai, UAE
Whole packs enter the network at Dubai — Jebel Ali Logistics Yard, 4,604 km away, where they are weighed and de-energised.
- 2
Graded at Stuttgart, Germany
Modules travel 321 km to Stuttgart — Baden-Wurttemberg Grading Works for capacity, resistance and impedance testing across all 8 modules.
- 3
Second-life build at Zwickau, Saxony
Grade A and B modules — about 47% of a pack at 80% SOH — are matched and rebuilt into storage systems on site.
- 4
Refined at Rotterdam, South Holland
Remaining modules are shredded to black mass and refined at Rotterdam — Maasvlakte Refining Works, 572 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Dubai — Jebel Ali Logistics Yard | 4,604 km |
| Nearest grading bench | Stuttgart — Baden-Wurttemberg Grading Works | 321 km |
| Nearest refinery | Rotterdam — Maasvlakte Refining Works | 572 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 Zwickau, Saxony 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
Zwickau, Saxony site notes
- Only graded modules are accepted.
- Modules need grade reports and traceable serial numbers.
- Finished systems are delivered on scheduled runs.
- Buyers can arrange site visits before purchase.
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 Germany
EU Battery Regulation (EU) 2023/1542 and national implementing law
Regulator: Umweltbundesamt (UBA) with registration through stiftung ear
Operations are subject to German permitting, including the Federal Immission Control Act where applicable, and to the EU Battery Regulation (EU) 2023/1542, which covers repurposed batteries and producer responsibility. Systems are built to applicable European safety standards.
BMW i4 eDrive40 in Zwickau, Saxony: common questions
Can I drop off a BMW i4 eDrive40 battery at Zwickau, Saxony?
Zwickau, Saxony is a second-life bess works and does not accept whole packs from customers. Book a collection and the pack enters the network at Dubai, UAE, 4,604 km away.
What happens to BMW i4 eDrive40 modules after Zwickau, Saxony?
Collected via Dubai, UAE, then Graded at Stuttgart, Germany, then Second-life build at Zwickau, Saxony, then Refined at Rotterdam, South Holland. 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 Germany?
EU Battery Regulation (EU) 2023/1542 and national implementing law, overseen by Umweltbundesamt (UBA) with registration through stiftung ear. Road transport follows ADR, and shipments out of Germany fall under the EU Waste Shipment Regulation.
BMW i4 eDrive40 at other sites
Retiring BMW i4 eDrive40 packs near Zwickau, Saxony?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.