Kia EV9 battery recycling in Chakan, Maharashtra
The Kia EV9 is not sold in India, so packs reach Chakan, Maharashtra through importers, research and test fleets or cross-border consolidation. They are accepted as whole packs, with extra checks on documentation and transboundary paperwork.
Pack value at 80% SOH
4,678 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
24,000 TPA
Integrated Recovery Campus
Cities served
12
From Chakan, Maharashtra
Where a Kia EV9 pack goes from Chakan, Maharashtra
- 1
Intake at Chakan, Maharashtra
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 468 km to Indore — Pithampur Grading Plant for capacity, resistance and impedance testing across all 36 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 (583 km). Good — grade-A modules above 80% SOH qualify for commercial-scale BESS strings.
- 4
Refined at Sriperumbudur, Tamil Nadu
Remaining modules are shredded to black mass and refined at Chennai — Sriperumbudur Recovery Campus, 916 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest grading bench | Indore — Pithampur Grading Plant | 468 km |
| Nearest second-life works | Nagpur — Butibori Second-Life Works | 583 km |
| Nearest refinery | Chennai — Sriperumbudur Recovery Campus | 916 km |
Faster option
Inside the Kia EV9 battery
The Kia EV9 (2024) carries a 99.8 kWh NMC 811 Cylindrical 2170 pack with 36 modules at 697 V, weighing roughly 559 kg. High-nickel cylindrical cells with the strongest hydrometallurgical recovery credit per tonne of black mass.
| Service year | SOH | Grade | Value |
|---|---|---|---|
| Year 2 | 94.6% | A — BESS ready | USD 6,243 |
| Year 4 | 90.3% | A — BESS ready | USD 5,995 |
| Year 6 | 86% | A — BESS ready | USD 5,673 |
| Year 8 | 81.7% | B — Second life | USD 4,934 |
| Year 10 | 77.4% | B — Second life | USD 4,324 |
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 Kia EV9 pack
99.8 kWh, 36 modules, about 559 kg — this is how the Chakan, 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
Chakan, Maharashtra site notes
- Suppliers inside Chakan MIDC can join a milk-run collection on fixed weekly days instead of booking one-off pickups.
- Segregate production scrap by chemistry and label it by cell format; mixed loads are re-sorted and take longer to settle.
- Car and two-wheeler pallets can be unloaded by forklift; bus and truck packs need advance notice so lifting gear is ready.
- Damaged units go straight to a thermally monitored quarantine store and are processed on a separate schedule.
What this pack yields
lithium
5.68 kg
nickel
36.66 kg
cobalt
4.54 kg
manganese
4.22 kg
copper
18.17 kg
aluminium
15.25 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 campus holds Maharashtra Pollution Control Board consent to operate as a battery waste processor and issues recovery evidence for producers under the CPCB EPR framework set by the Battery Waste Management Rules 2022. Shredding and black mass handling carry additional dust, effluent and fire-safety conditions tied to the MIDC plot, and outgoing black mass travels with assay and custody records.
Kia EV9 in Chakan, Maharashtra: common questions
Can I drop off a Kia EV9 battery at Chakan, Maharashtra?
Yes, by appointment. Pune — Chakan Industrial Recovery Campus accepts whole Kia EV9 packs; book a collection or a drop-off slot so the site can prepare packaging and paperwork.
What happens to Kia EV9 modules after Chakan, Maharashtra?
Intake at Chakan, Maharashtra, then Graded at Pithampur, Madhya Pradesh, then Second life at Butibori, Maharashtra, then Refined at Sriperumbudur, Tamil Nadu. At 80% SOH roughly 47% of the pack goes to second life and the rest is refined.
How should a Kia EV9 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 Kia EV9 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 Chakan, Maharashtra
Kia EV9 at other sites
Other passenger packs at Chakan, Maharashtra
Retiring Kia EV9 packs near Chakan, Maharashtra?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.