Hyundai Ioniq 5 (E-GMP) battery recycling in Sanand, Gujarat
Gujarat — Sanand Reverse Logistics Yard takes whole Hyundai Ioniq 5 (E-GMP) 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
3,403 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
21,000 TPA
Reverse Logistics Yard
Cities served
7
From Sanand, Gujarat
Where a Hyundai Ioniq 5 (E-GMP) pack goes from Sanand, Gujarat
- 1
Intake at Sanand, Gujarat
One pack per UN-rated pallet box, strapped and restrained, with terminals capped and coolant ports sealed. Each pack is weighed, photographed and discharged below 30% state of charge.
- 2
Graded at Pithampur, Madhya Pradesh
Modules travel 341 km to Indore — Pithampur Grading Plant for capacity, resistance and impedance testing across all 32 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 (714 km). Good — grade-A modules above 80% SOH qualify for commercial-scale BESS strings.
- 4
Refined at Atchutapuram, Andhra Pradesh
Remaining modules are shredded to black mass and refined at Visakhapatnam — Atchutapuram Refinery, 1,249 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest grading bench | Indore — Pithampur Grading Plant | 341 km |
| Nearest second-life works | Nagpur — Butibori Second-Life Works | 714 km |
| Nearest refinery | Visakhapatnam — Atchutapuram Refinery | 1,249 km |
Inside the Hyundai Ioniq 5 (E-GMP) battery
The Hyundai Ioniq 5 (E-GMP) (2022) carries a 72.6 kWh NMC 811 Cylindrical 2170 pack with 32 modules at 697 V, weighing roughly 407 kg. High-nickel cylindrical cells with the strongest hydrometallurgical recovery credit per tonne of black mass.
| Service year | SOH | Grade | Value |
|---|---|---|---|
| Year 2 | 95.3% | A — BESS ready | USD 4,571 |
| Year 4 | 91% | A — BESS ready | USD 4,390 |
| Year 6 | 86.7% | A — BESS ready | USD 4,210 |
| Year 8 | 82.4% | B — Second life | USD 3,671 |
| Year 10 | 78.1% | B — Second life | USD 3,212 |
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 Hyundai Ioniq 5 (E-GMP) pack
72.6 kWh, 32 modules, about 407 kg — this is how the Sanand, Gujarat 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
Sanand, Gujarat site notes
- Plants in Sanand GIDC can align scheduled pickups with their shift patterns to avoid blocking loading docks.
- Ask for UN-approved containers at booking if you do not hold your own; they are delivered before the collection date.
- Declare state of charge; packs above 30% SOC are discharged at the yard before they are forwarded.
- Damaged packs are moved into steel containment immediately on arrival and forwarded under separate paperwork.
What this pack yields
lithium
4.13 kg
nickel
26.67 kg
cobalt
3.3 kg
manganese
3.07 kg
copper
13.22 kg
aluminium
11.09 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 yard operates under Gujarat Pollution Control Board authorisation for storing and handling battery waste. It sits within the Battery Waste Management Rules 2022 chain as a collection and storage point, issuing custody records that follow each unit to the registered recycler that ultimately generates the producer's EPR evidence.
Hyundai Ioniq 5 (E-GMP) in Sanand, Gujarat: common questions
Can I drop off a Hyundai Ioniq 5 (E-GMP) battery at Sanand, Gujarat?
Yes, by appointment. Gujarat — Sanand Reverse Logistics Yard accepts whole Hyundai Ioniq 5 (E-GMP) packs; book a collection or a drop-off slot so the site can prepare packaging and paperwork.
What happens to Hyundai Ioniq 5 (E-GMP) modules after Sanand, Gujarat?
Intake at Sanand, Gujarat, then Graded at Pithampur, Madhya Pradesh, then Second life at Butibori, Maharashtra, then Refined at Atchutapuram, Andhra Pradesh. At 80% SOH roughly 47% of the pack goes to second life and the rest is refined.
How should a Hyundai Ioniq 5 (E-GMP) 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 Hyundai Ioniq 5 (E-GMP) 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.
Cities collected by Sanand, Gujarat
Hyundai Ioniq 5 (E-GMP) at other sites
Retiring Hyundai Ioniq 5 (E-GMP) packs near Sanand, Gujarat?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.