MG Windsor EV battery recycling in Zaheerabad, Telangana
Hyderabad — Zaheerabad Recovery Campus takes whole MG Windsor EV 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
1,217 USD
Hybrid Split
Second-life share
56%
At 80% SOH
Site capacity
17,000 TPA
Integrated Recovery Campus
Cities served
0
From Zaheerabad, Telangana
Where a MG Windsor EV pack goes from Zaheerabad, Telangana
- 1
Intake at Zaheerabad, Telangana
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 Hosur, Tamil Nadu
Modules travel 550 km to Bengaluru — Hosur Diagnostics Centre for capacity, resistance and impedance testing across all 12 modules.
- 3
Second life at Butibori, Maharashtra
At 80% SOH about 56% of the pack qualifies for reuse and goes to Nagpur — Butibori Second-Life Works (387 km). Excellent — long calendar life makes LFP the preferred feedstock for stationary BESS repurposing.
- 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 grading bench | Bengaluru — Hosur Diagnostics Centre | 550 km |
| Nearest second-life works | Nagpur — Butibori Second-Life Works | 387 km |
| Nearest refinery | Visakhapatnam — Atchutapuram Refinery | 558 km |
Inside the MG Windsor EV battery
The MG Windsor EV (2024) carries a 38 kWh LFP Prismatic (LiFePO4) pack with 12 modules at 340 V, weighing roughly 281 kg. Cobalt-free prismatic chemistry dominant in Indian passenger EVs and commercial fleets. Low black mass value, exceptional second-life economics.
| Service year | SOH | Grade | Value |
|---|---|---|---|
| Year 2 | 95.9% | A — BESS ready | USD 1,987 |
| Year 4 | 92.8% | A — BESS ready | USD 1,924 |
| Year 6 | 89.7% | A — BESS ready | USD 1,862 |
| Year 8 | 86.6% | A — BESS ready | USD 1,799 |
| Year 10 | 83.5% | B — Second life | USD 1,514 |
What the chemistry means here
How it ages
LFP fades slowly and fairly linearly for most of its life. Capacity loss is driven mainly by lithium inventory being locked up in the SEI layer on the graphite anode, while the cathode structure stays largely intact.
Thermal behaviour
LFP's olivine cathode holds its oxygen tightly, so thermal runaway typically starts at higher temperatures than nickel-rich cells and releases noticeably less heat. It is not inert: a failing LFP cell still vents flammable electrolyte vapour and hydrogen, and large prismatic cans store a lot of energy in one place.
Handling LFP Prismatic
Collecting a MG Windsor EV pack
38 kWh, 12 modules, about 281 kg — this is how the Zaheerabad, Telangana 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
Zaheerabad, Telangana site notes
- Bus packs require advance notice so lifting equipment and a trained crew are scheduled.
- Share pack drawings or architecture notes for unfamiliar commercial formats before collection.
- Hyderabad fleet depots can book recurring scheduled collections.
- Damaged units are received in a dedicated quarantine building away from the main floor.
What this pack yields
lithium
2.82 kg
nickel
0 kg
cobalt
0 kg
manganese
0 kg
copper
8.52 kg
aluminium
10.17 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 operates under Telangana State Pollution Control Board consent within the Zaheerabad NIMZ, with conditions covering shredding, dust control and fire safety. It issues recovery evidence for producers registered under the Battery Waste Management Rules 2022.
MG Windsor EV in Zaheerabad, Telangana: common questions
Can I drop off a MG Windsor EV battery at Zaheerabad, Telangana?
Yes, by appointment. Hyderabad — Zaheerabad Recovery Campus accepts whole MG Windsor EV packs; book a collection or a drop-off slot so the site can prepare packaging and paperwork.
What happens to MG Windsor EV modules after Zaheerabad, Telangana?
Intake at Zaheerabad, Telangana, then Graded at Hosur, Tamil Nadu, then Second life at Butibori, Maharashtra, then Refined at Atchutapuram, Andhra Pradesh. At 80% SOH roughly 56% of the pack goes to second life and the rest is refined.
How should a MG Windsor EV 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 MG Windsor EV 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.
MG Windsor EV at other sites
Other passenger packs at Zaheerabad, Telangana
Retiring MG Windsor EV packs near Zaheerabad, Telangana?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.