Ford F-150 Lightning ER battery recycling in Detroit, Michigan
Detroit — Michigan Closed-Loop Plant takes whole Ford F-150 Lightning ER packs straight from fleets, dealers and workshops. Packs are weighed, de-energised and logged here before modules move on for grading or refining.
Pack value at 80% SOH
6,140 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
40,000 TPA
Integrated Recovery Campus
Cities served
10
From Detroit, Michigan
Where a Ford F-150 Lightning ER pack goes from Detroit, Michigan
- 1
Intake at Detroit, Michigan
Each pack travels in a rated crate or on a restrained pallet, with coolant drained and ports sealed. Each pack is weighed, photographed and discharged below 30% state of charge.
- 2
Graded at Atlanta, Georgia
Modules travel 961 km to Atlanta — Georgia Grading Centre for capacity, resistance and impedance testing across all 16 modules.
- 3
Second life at Gothenburg, Sweden
At 80% SOH about 47% of the pack qualifies for reuse and goes to Gothenburg — Nordic Second-Life Campus (6,413 km). Good — grade-A modules above 80% SOH qualify for commercial-scale BESS strings.
- 4
Refined at Reno, Nevada
Remaining modules are shredded to black mass and refined at Reno — Nevada Hydrometallurgy Refinery, 3,080 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest grading bench | Atlanta — Georgia Grading Centre | 961 km |
| Nearest second-life works | Gothenburg — Nordic Second-Life Campus | 6,413 km |
| Nearest refinery | Reno — Nevada Hydrometallurgy Refinery | 3,080 km |
Inside the Ford F-150 Lightning ER battery
The Ford F-150 Lightning ER (2022) carries a 131 kWh NMC 811 Cylindrical 2170 pack with 16 modules at 400 V, weighing roughly 734 kg. High-nickel cylindrical cells with the strongest hydrometallurgical recovery credit per tonne of black mass.
| Service year | SOH | Grade | Value |
|---|---|---|---|
| Year 2 | 95.6% | A — BESS ready | USD 8,271 |
| Year 4 | 91.3% | A — BESS ready | USD 7,945 |
| Year 6 | 87% | A — BESS ready | USD 7,619 |
| Year 8 | 82.7% | B — Second life | USD 6,687 |
| Year 10 | 78.4% | B — Second life | USD 5,847 |
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 Ford F-150 Lightning ER pack
131 kWh, 16 modules, about 734 kg — this is how the Detroit, Michigan team plans the job.
Removal
Large packs are removed at the depot with a forklift-rated battery table and the vehicle isolated under lock-out tag-out.
Packaging
Each pack travels in a rated crate or on a restrained pallet, with coolant drained and ports sealed.
Consolidation
Depot retirements are batched against the fleet replacement schedule so collections line up with vehicle swaps.
Before the truck arrives
- Share telematics SOH history if it is available
- Confirm forklift access and dock height at the depot
- Isolate high-voltage systems under lock-out tag-out
- Declare any pack involved in a collision
Detroit, Michigan site notes
- Send architecture drawings or a disassembly note with prototype packs so the right procedure is prepared.
- Engineering centres can book recurring collections for validation and test waste.
- Damaged, defective or recalled units must be declared so they ship under the correct DOT provisions.
- Truck and large commercial packs need advance notice so rigging and crew are scheduled.
What this pack yields
lithium
7.45 kg
nickel
48.13 kg
cobalt
5.96 kg
manganese
5.54 kg
copper
23.85 kg
aluminium
20.02 kg
Refining-route estimate at 80% SOH. Measured module health on the bench sets the final split.
Rules in United States
EPA universal waste rules, DOT hazardous materials regulations and state programmes
Regulator: EPA, DOT PHMSA and state environmental agencies
The campus operates under permits administered by Michigan's Department of Environment, Great Lakes, and Energy (EGLE), and manages spent lithium-ion batteries under the US EPA universal waste framework where it applies. Transport follows US DOT hazardous materials regulations for lithium batteries, including the separate provisions for damaged, defective or recalled cells.
Ford F-150 Lightning ER in Detroit, Michigan: common questions
Can I drop off a Ford F-150 Lightning ER battery at Detroit, Michigan?
Yes, by appointment. Detroit — Michigan Closed-Loop Plant accepts whole Ford F-150 Lightning ER packs; book a collection or a drop-off slot so the site can prepare packaging and paperwork.
What happens to Ford F-150 Lightning ER modules after Detroit, Michigan?
Intake at Detroit, Michigan, then Graded at Atlanta, Georgia, then Second life at Gothenburg, Sweden, then Refined at Reno, Nevada. At 80% SOH roughly 47% of the pack goes to second life and the rest is refined.
How should a Ford F-150 Lightning ER pack be prepared for pickup?
Share telematics SOH history if it is available. Confirm forklift access and dock height at the depot. Isolate high-voltage systems under lock-out tag-out. Declare any pack involved in a collision.
Which rules apply to Ford F-150 Lightning ER recycling in United States?
EPA universal waste rules, DOT hazardous materials regulations and state programmes, overseen by EPA, DOT PHMSA and state environmental agencies. Shipments follow DOT PHMSA 49 CFR requirements, with damaged or defective batteries under stricter special permits and packaging.
Cities collected by Detroit, Michigan
Ford F-150 Lightning ER at other sites
Other commercial fleet packs at Detroit, Michigan
Retiring Ford F-150 Lightning ER packs near Detroit, Michigan?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.