BYD Atto 3 battery recycling in Kalamassery, Kerala
Kalamassery, Kerala is a diagnostics site: BYD Atto 3 packs arrive here from intake yards for module-level capacity, resistance and impedance testing, which decides reuse or refining.
Pack value at 80% SOH
1,938 USD
Hybrid Split
Second-life share
56%
At 80% SOH
Site capacity
7,000 TPA
Cell Grading & Diagnostics
Cities served
0
From Kalamassery, Kerala
Where a BYD Atto 3 pack goes from Kalamassery, Kerala
- 1
Collected via Zaheerabad, Telangana
Whole packs enter the network at Hyderabad — Zaheerabad Recovery Campus, 860 km away, where they are weighed and de-energised.
- 2
Module grading at Kalamassery, Kerala
All 1 modules are tested for capacity, DC resistance and impedance, then assigned grade A to D.
- 3
Second life at Butibori, Maharashtra
At 80% SOH about 56% of the pack qualifies for reuse and goes to Nagpur — Butibori Second-Life Works (1,242 km). Excellent — long calendar life makes LFP the preferred feedstock for stationary BESS repurposing.
- 4
Refined at Sriperumbudur, Tamil Nadu
Remaining modules are shredded to black mass and refined at Chennai — Sriperumbudur Recovery Campus, 510 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Hyderabad — Zaheerabad Recovery Campus | 860 km |
| Nearest second-life works | Nagpur — Butibori Second-Life Works | 1,242 km |
| Nearest refinery | Chennai — Sriperumbudur Recovery Campus | 510 km |
Faster option
Inside the BYD Atto 3 battery
The BYD Atto 3 (2022) carries a 60.5 kWh LFP Prismatic (LiFePO4) pack with 1 modules at 400 V, weighing roughly 448 kg. Cobalt-free prismatic chemistry dominant in Indian passenger EVs and commercial fleets. Low black mass value, exceptional second-life economics.
| Service year | SOH | Grade | Value |
|---|---|---|---|
| Year 2 | 96.5% | A — BESS ready | USD 3,183 |
| Year 4 | 93.4% | A — BESS ready | USD 3,083 |
| Year 6 | 90.3% | A — BESS ready | USD 2,983 |
| Year 8 | 87.2% | A — BESS ready | USD 2,883 |
| Year 10 | 84.1% | B — Second life | USD 2,496 |
What the chemistry means here
How it ages
LFP fades slowly and fairly linearly for most of its life. Capacity loss is driven mainly by lithium inventory being locked up in the SEI layer on the graphite anode, while the cathode structure stays largely intact.
Thermal behaviour
LFP's olivine cathode holds its oxygen tightly, so thermal runaway typically starts at higher temperatures than nickel-rich cells and releases noticeably less heat. It is not inert: a failing LFP cell still vents flammable electrolyte vapour and hydrogen, and large prismatic cans store a lot of energy in one place.
Handling LFP Prismatic
Collecting a BYD Atto 3 pack
60.5 kWh, 1 modules, about 448 kg — this is how the Kalamassery, Kerala 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
Kalamassery, Kerala site notes
- Heavy commercial packs are routed to larger sites with lifting equipment.
- Keep packs covered during loading, especially in the monsoon months.
- Send a serial list with every consignment.
- Declare any water ingress or swelling at booking so the pack is isolated on arrival.
What this pack yields
lithium
4.49 kg
nickel
0 kg
cobalt
0 kg
manganese
0 kg
copper
13.57 kg
aluminium
16.2 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 bench operates under Kerala State Pollution Control Board consent within a KINFRA park and grades material for producers under the Battery Waste Management Rules 2022, with custody records passed on to the downstream recycler.
BYD Atto 3 in Kalamassery, Kerala: common questions
Can I drop off a BYD Atto 3 battery at Kalamassery, Kerala?
Kalamassery, Kerala is a cell grading & diagnostics and does not accept whole packs from customers. Book a collection and the pack enters the network at Zaheerabad, Telangana, 860 km away.
What happens to BYD Atto 3 modules after Kalamassery, Kerala?
Collected via Zaheerabad, Telangana, then Module grading at Kalamassery, Kerala, then Second life at Butibori, Maharashtra, then Refined at Sriperumbudur, Tamil Nadu. At 80% SOH roughly 56% of the pack goes to second life and the rest is refined.
How should a BYD Atto 3 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 BYD Atto 3 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.
BYD Atto 3 at other sites
Other passenger packs at Kalamassery, Kerala
Retiring BYD Atto 3 packs near Kalamassery, Kerala?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.