Hyundai Ioniq 5 (E-GMP) battery recycling in Butibori, Maharashtra
Butibori, Maharashtra receives graded Hyundai Ioniq 5 (E-GMP) modules that passed as grade A or B and rebuilds them into warrantied stationary storage.
Pack value at 80% SOH
3,403 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
9,500 TPA
Second-Life BESS Works
Cities served
0
From Butibori, Maharashtra
Where a Hyundai Ioniq 5 (E-GMP) pack goes from Butibori, Maharashtra
- 1
Collected via Zaheerabad, Telangana
Whole packs enter the network at Hyderabad — Zaheerabad Recovery Campus, 387 km away, where they are weighed and de-energised.
- 2
Graded at Pithampur, Madhya Pradesh
Modules travel 385 km to Indore — Pithampur Grading Plant for capacity, resistance and impedance testing across all 32 modules.
- 3
Second-life build at Butibori, Maharashtra
Grade A and B modules — about 47% of a pack at 80% SOH — are matched and rebuilt into storage systems on site.
- 4
Refined at Atchutapuram, Andhra Pradesh
Remaining modules are shredded to black mass and refined at Visakhapatnam — Atchutapuram Refinery, 558 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Hyderabad — Zaheerabad Recovery Campus | 387 km |
| Nearest grading bench | Indore — Pithampur Grading Plant | 385 km |
| Nearest refinery | Visakhapatnam — Atchutapuram Refinery | 558 km |
Faster option
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 Butibori, Maharashtra 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
Butibori, Maharashtra site notes
- Whole packs are not accepted; modules must arrive already graded.
- Each module needs its grade report and serial number.
- Finished units are dispatched on scheduled delivery runs agreed with the buyer.
- Buyers can inspect systems before dispatch by appointment.
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 works operates under Maharashtra Pollution Control Board consent. Repurposed storage systems are built to applicable Indian electrical and safety requirements, and the provenance of every module is recorded so each system can be traced back to its source packs.
Hyundai Ioniq 5 (E-GMP) in Butibori, Maharashtra: common questions
Can I drop off a Hyundai Ioniq 5 (E-GMP) battery at Butibori, Maharashtra?
Butibori, Maharashtra is a second-life bess works and does not accept whole packs from customers. Book a collection and the pack enters the network at Zaheerabad, Telangana, 387 km away.
What happens to Hyundai Ioniq 5 (E-GMP) modules after Butibori, Maharashtra?
Collected via Zaheerabad, Telangana, then Graded at Pithampur, Madhya Pradesh, then Second-life build 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.
Hyundai Ioniq 5 (E-GMP) at other sites
Other passenger packs at Butibori, Maharashtra
Retiring Hyundai Ioniq 5 (E-GMP) packs near Butibori, Maharashtra?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.