Ford F-150 Lightning ER battery recycling in Atchutapuram, Andhra Pradesh
Atchutapuram, Andhra Pradesh does not take whole packs. It receives black mass made from Ford F-150 Lightning ER modules that failed grading, and turns it into battery-grade salts.
Pack value at 80% SOH
6,140 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
13,000 TPA
Hydrometallurgical Refinery
Cities served
0
From Atchutapuram, Andhra Pradesh
Where a Ford F-150 Lightning ER pack goes from Atchutapuram, Andhra Pradesh
- 1
Collected via Khordha, Odisha
Whole packs enter the network at Bhubaneswar — Khordha Collection Yard, 411 km away, where they are weighed and de-energised.
- 2
Graded at Hosur, Tamil Nadu
Modules travel 761 km to Bengaluru — Hosur Diagnostics Centre for capacity, resistance and impedance testing across all 16 modules.
- 3
Second life at Butibori, Maharashtra
At 80% SOH about 47% of the pack qualifies for reuse and goes to Nagpur — Butibori Second-Life Works (558 km). Good — grade-A modules above 80% SOH qualify for commercial-scale BESS strings.
- 4
Refining at Atchutapuram, Andhra Pradesh
Black mass from failed modules is leached and refined here into battery-grade nickel, cobalt and lithium salts.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Bhubaneswar — Khordha Collection Yard | 411 km |
| Nearest grading bench | Bengaluru — Hosur Diagnostics Centre | 761 km |
| Nearest second-life works | Nagpur — Butibori Second-Life Works | 558 km |
Faster option
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 Atchutapuram, Andhra Pradesh 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
Atchutapuram, Andhra Pradesh site notes
- Only black mass and cathode scrap are accepted at this site.
- Bulk bags must be sealed, labelled and accompanied by declared chemistry.
- Port-linked consignments need documentation before arrival.
- Sampling at intake determines settlement; results are shared with the consignor.
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 India
Battery Waste Management Rules 2022 (BWMR)
Regulator: Central Pollution Control Board (CPCB) and State Pollution Control Boards
The refinery operates under Andhra Pradesh Pollution Control Board consent, with conditions covering effluent treatment, air emissions and hazardous chemical storage. As a registered recycler it generates recovery evidence for producers under the Battery Waste Management Rules 2022, and port-linked movements follow customs and applicable waste-shipment controls.
Ford F-150 Lightning ER in Atchutapuram, Andhra Pradesh: common questions
Can I drop off a Ford F-150 Lightning ER battery at Atchutapuram, Andhra Pradesh?
Atchutapuram, Andhra Pradesh is a hydrometallurgical refinery and does not accept whole packs from customers. Book a collection and the pack enters the network at Khordha, Odisha, 411 km away.
What happens to Ford F-150 Lightning ER modules after Atchutapuram, Andhra Pradesh?
Collected via Khordha, Odisha, then Graded at Hosur, Tamil Nadu, then Second life at Butibori, Maharashtra, then Refining at Atchutapuram, Andhra Pradesh. 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 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.
Ford F-150 Lightning ER at other sites
Other commercial fleet packs at Atchutapuram, Andhra Pradesh
Retiring Ford F-150 Lightning ER packs near Atchutapuram, Andhra Pradesh?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.