Nissan Leaf ZE1 battery recycling in Butibori, Maharashtra
Butibori, Maharashtra receives graded Nissan Leaf ZE1 modules that passed as grade A or B and rebuilds them into warrantied stationary storage.
Pack value at 80% SOH
1,167 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 Nissan Leaf ZE1 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 24 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 Nissan Leaf ZE1 battery
The Nissan Leaf ZE1 (2018) carries a 40 kWh LMO / LMO-NMC Pouch pack with 24 modules at 350 V, weighing roughly 324 kg. Legacy manganese-rich pouch packs common in early two- and three-wheeler fleets across South Asia.
| Service year | SOH | Grade | Value |
|---|---|---|---|
| Year 2 | 95.4% | A — BESS ready | USD 1,450 |
| Year 4 | 91.1% | A — BESS ready | USD 1,394 |
| Year 6 | 86.8% | A — BESS ready | USD 1,339 |
| Year 8 | 82.5% | B — Second life | USD 1,223 |
| Year 10 | 78.2% | B — Second life | USD 1,132 |
What the chemistry means here
How it ages
LMO's weak point is manganese dissolution, which speeds up at elevated temperature and damages the anode. Packs that lived in hot climates without active cooling typically fade faster.
Thermal behaviour
Manganese spinel is more thermally stable than nickel-rich cathodes, but blended LMO-NMC pouch cells still vent flammable gas when abused, and older packs may have weaker protection electronics.
Handling LMO Pouch
Collecting a Nissan Leaf ZE1 pack
40 kWh, 24 modules, about 324 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
2.82 kg
nickel
6.02 kg
cobalt
0.85 kg
manganese
17.59 kg
copper
11.1 kg
aluminium
12.41 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.
Nissan Leaf ZE1 in Butibori, Maharashtra: common questions
Can I drop off a Nissan Leaf ZE1 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 Nissan Leaf ZE1 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 Nissan Leaf ZE1 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 Nissan Leaf ZE1 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.
Nissan Leaf ZE1 at other sites
Other passenger packs at Butibori, Maharashtra
Retiring Nissan Leaf ZE1 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.