Nissan Leaf ZE1 battery recycling in Zwickau, Saxony
Zwickau, Saxony 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
20,000 TPA
Second-Life BESS Works
Cities served
0
From Zwickau, Saxony
Where a Nissan Leaf ZE1 pack goes from Zwickau, Saxony
- 1
Collected via Dubai, UAE
Whole packs enter the network at Dubai — Jebel Ali Logistics Yard, 4,604 km away, where they are weighed and de-energised.
- 2
Graded at Stuttgart, Germany
Modules travel 321 km to Stuttgart — Baden-Wurttemberg Grading Works for capacity, resistance and impedance testing across all 24 modules.
- 3
Second-life build at Zwickau, Saxony
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 Rotterdam, South Holland
Remaining modules are shredded to black mass and refined at Rotterdam — Maasvlakte Refining Works, 572 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Dubai — Jebel Ali Logistics Yard | 4,604 km |
| Nearest grading bench | Stuttgart — Baden-Wurttemberg Grading Works | 321 km |
| Nearest refinery | Rotterdam — Maasvlakte Refining Works | 572 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 Zwickau, Saxony 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
Zwickau, Saxony site notes
- Only graded modules are accepted.
- Modules need grade reports and traceable serial numbers.
- Finished systems are delivered on scheduled runs.
- Buyers can arrange site visits before purchase.
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 Germany
EU Battery Regulation (EU) 2023/1542 and national implementing law
Regulator: Umweltbundesamt (UBA) with registration through stiftung ear
Operations are subject to German permitting, including the Federal Immission Control Act where applicable, and to the EU Battery Regulation (EU) 2023/1542, which covers repurposed batteries and producer responsibility. Systems are built to applicable European safety standards.
Nissan Leaf ZE1 in Zwickau, Saxony: common questions
Can I drop off a Nissan Leaf ZE1 battery at Zwickau, Saxony?
Zwickau, Saxony is a second-life bess works and does not accept whole packs from customers. Book a collection and the pack enters the network at Dubai, UAE, 4,604 km away.
What happens to Nissan Leaf ZE1 modules after Zwickau, Saxony?
Collected via Dubai, UAE, then Graded at Stuttgart, Germany, then Second-life build at Zwickau, Saxony, then Refined at Rotterdam, South Holland. 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 Germany?
EU Battery Regulation (EU) 2023/1542 and national implementing law, overseen by Umweltbundesamt (UBA) with registration through stiftung ear. Road transport follows ADR, and shipments out of Germany fall under the EU Waste Shipment Regulation.
Nissan Leaf ZE1 at other sites
Retiring Nissan Leaf ZE1 packs near Zwickau, Saxony?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.