Ola Electric S1 X+ battery recycling in Kalamassery, Kerala
Kalamassery, Kerala is a diagnostics site: Ola Electric S1 X+ packs arrive here from intake yards for module-level capacity, resistance and impedance testing, which decides reuse or refining.
Pack value at 80% SOH
112 USD
Hybrid Split
Second-life share
56%
At 80% SOH
Site capacity
7,000 TPA
Cell Grading & Diagnostics
Cities served
0
From Kalamassery, Kerala
Where a Ola Electric S1 X+ pack goes from Kalamassery, Kerala
- 1
Collected via Zaheerabad, Telangana
Whole packs enter the network at Hyderabad — Zaheerabad Recovery Campus, 860 km away, where they are weighed and de-energised.
- 2
Module grading at Kalamassery, Kerala
All 2 modules are tested for capacity, DC resistance and impedance, then assigned grade A to D.
- 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 (1,242 km). Excellent — long calendar life makes LFP the preferred feedstock for stationary BESS repurposing.
- 4
Refined at Sriperumbudur, Tamil Nadu
Remaining modules are shredded to black mass and refined at Chennai — Sriperumbudur Recovery Campus, 510 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Hyderabad — Zaheerabad Recovery Campus | 860 km |
| Nearest second-life works | Nagpur — Butibori Second-Life Works | 1,242 km |
| Nearest refinery | Chennai — Sriperumbudur Recovery Campus | 510 km |
Faster option
Inside the Ola Electric S1 X+ battery
The Ola Electric S1 X+ (2024) carries a 3.5 kWh LFP Prismatic (LiFePO4) pack with 2 modules at 48 V, weighing roughly 26 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 | 96.3% | A — BESS ready | USD 184 |
| Year 4 | 93.2% | A — BESS ready | USD 178 |
| Year 6 | 90.1% | A — BESS ready | USD 172 |
| Year 8 | 87% | A — BESS ready | USD 166 |
| Year 10 | 83.9% | B — Second life | USD 143 |
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 Ola Electric S1 X+ pack
3.5 kWh, 2 modules, about 26 kg — this is how the Kalamassery, Kerala team plans the job.
Removal
Removable packs are unclipped by hand; fixed packs are removed at the dealer bench with the frame supported.
Packaging
Packs travel in UN-approved steel or plastic cages with non-conductive dividers, typically dozens per cage.
Consolidation
Dealer and swap-station returns are aggregated at a single point so one collection clears many units.
Before the truck arrives
- Tape terminals and connectors on every pack
- Separate swollen or dropped packs into their own container
- Record serials in a single list per cage
- Store below 30% charge away from charging racks
Kalamassery, Kerala site notes
- Heavy commercial packs are routed to larger sites with lifting equipment.
- Keep packs covered during loading, especially in the monsoon months.
- Send a serial list with every consignment.
- Declare any water ingress or swelling at booking so the pack is isolated on arrival.
What this pack yields
lithium
0.26 kg
nickel
0 kg
cobalt
0 kg
manganese
0 kg
copper
0.79 kg
aluminium
0.94 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 bench operates under Kerala State Pollution Control Board consent within a KINFRA park and grades material for producers under the Battery Waste Management Rules 2022, with custody records passed on to the downstream recycler.
Ola Electric S1 X+ in Kalamassery, Kerala: common questions
Can I drop off a Ola Electric S1 X+ battery at Kalamassery, Kerala?
Kalamassery, Kerala is a cell grading & diagnostics and does not accept whole packs from customers. Book a collection and the pack enters the network at Zaheerabad, Telangana, 860 km away.
What happens to Ola Electric S1 X+ modules after Kalamassery, Kerala?
Collected via Zaheerabad, Telangana, then Module grading at Kalamassery, Kerala, then Second life at Butibori, Maharashtra, then Refined at Sriperumbudur, Tamil Nadu. At 80% SOH roughly 56% of the pack goes to second life and the rest is refined.
How should a Ola Electric S1 X+ pack be prepared for pickup?
Tape terminals and connectors on every pack. Separate swollen or dropped packs into their own container. Record serials in a single list per cage. Store below 30% charge away from charging racks.
Which rules apply to Ola Electric S1 X+ 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.
Ola Electric S1 X+ at other sites
Other two-wheeler packs at Kalamassery, Kerala
Retiring Ola Electric S1 X+ packs near Kalamassery, Kerala?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.