Nissan Leaf ZE1 battery recycling in Chakan, Maharashtra
The Nissan Leaf ZE1 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
1,167 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 Nissan Leaf ZE1 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 24 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). Limited — accelerated manganese dissolution caps second-life warranty terms at 36 months.
- 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 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 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
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 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.
Nissan Leaf ZE1 in Chakan, Maharashtra: common questions
Can I drop off a Nissan Leaf ZE1 battery at Chakan, Maharashtra?
Yes, by appointment. Pune — Chakan Industrial Recovery Campus accepts whole Nissan Leaf ZE1 packs; book a collection or a drop-off slot so the site can prepare packaging and paperwork.
What happens to Nissan Leaf ZE1 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 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.
Cities collected by Chakan, Maharashtra
Nissan Leaf ZE1 at other sites
Other passenger packs at Chakan, Maharashtra
Retiring Nissan Leaf ZE1 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.