Ford F-150 Lightning ER battery recycling in Ulsan, South Korea
Ulsan — Korea Recovery Campus 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
34,000 TPA
Integrated Recovery Campus
Cities served
2
From Ulsan, South Korea
Where a Ford F-150 Lightning ER pack goes from Ulsan, South Korea
- 1
Intake at Ulsan, South Korea
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 Yokohama, Kanagawa
Modules travel 935 km to Yokohama — Kanagawa Diagnostics Works 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 (8,121 km). Good — grade-A modules above 80% SOH qualify for commercial-scale BESS strings.
- 4
Refined at Ningde, Fujian
Remaining modules are shredded to black mass and refined at Ningde — Fujian Refining Base, 1,354 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest grading bench | Yokohama — Kanagawa Diagnostics Works | 935 km |
| Nearest second-life works | Gothenburg — Nordic Second-Life Campus | 8,121 km |
| Nearest refinery | Ningde — Fujian Refining Base | 1,354 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 Ulsan, South Korea 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
Ulsan, South Korea site notes
- Manufacturers can arrange recurring scrap collections.
- Declare chemistry and format at booking.
- Large packs need advance notice.
- Damaged units require special handling.
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 South Korea
Act on Resource Circulation of Electrical and Electronic Equipment and Vehicles
Regulator: Ministry of Environment, with Korea Environment Corporation
The campus operates under Korean environmental permitting and national rules on waste and resource recycling, including producer responsibility schemes. Transport follows Korean dangerous goods regulations.
Ford F-150 Lightning ER in Ulsan, South Korea: common questions
Can I drop off a Ford F-150 Lightning ER battery at Ulsan, South Korea?
Yes, by appointment. Ulsan — Korea Recovery Campus 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 Ulsan, South Korea?
Intake at Ulsan, South Korea, then Graded at Yokohama, Kanagawa, then Second life at Gothenburg, Sweden, then Refined at Ningde, Fujian. 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 South Korea?
Act on Resource Circulation of Electrical and Electronic Equipment and Vehicles, overseen by Ministry of Environment, with Korea Environment Corporation. Transport follows national dangerous goods rules, with lithium-ion batteries packaged under UN 3480 / UN 3481.
Cities collected by Ulsan, South Korea
Ford F-150 Lightning ER at other sites
Other commercial fleet packs at Ulsan, South Korea
Retiring Ford F-150 Lightning ER packs near Ulsan, South Korea?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.