Renault Zoe R135 battery recycling in Kalamassery, Kerala
Kalamassery, Kerala is a diagnostics site: Renault Zoe R135 packs arrive here from intake yards for module-level capacity, resistance and impedance testing, which decides reuse or refining.
Pack value at 80% SOH
2,437 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
7,000 TPA
Cell Grading & Diagnostics
Cities served
0
From Kalamassery, Kerala
Where a Renault Zoe R135 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 12 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 47% of the pack qualifies for reuse and goes to Nagpur — Butibori Second-Life Works (1,242 km). Good — grade-A modules above 80% SOH qualify for commercial-scale BESS strings.
- 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 Renault Zoe R135 battery
The Renault Zoe R135 (2019) carries a 52 kWh NMC 811 Cylindrical 2170 pack with 12 modules at 400 V, weighing roughly 291 kg. High-nickel cylindrical cells with the strongest hydrometallurgical recovery credit per tonne of black mass.
| Service year | SOH | Grade | Value |
|---|---|---|---|
| Year 2 | 94.7% | A — BESS ready | USD 3,256 |
| Year 4 | 90.4% | A — BESS ready | USD 3,127 |
| Year 6 | 86.1% | A — BESS ready | USD 2,966 |
| Year 8 | 81.8% | B — Second life | USD 2,579 |
| Year 10 | 77.5% | B — Second life | USD 2,260 |
What the chemistry means here
How it ages
NMC 811 loses capacity through a mix of SEI growth, cathode surface reconstruction and micro-cracking of nickel-rich particles. Resistance climbs faster than in LFP, which matters as much as capacity for second-life duty.
Thermal behaviour
High-nickel NMC cathodes release oxygen as they decompose, so once runaway starts it is fast and energetic. Cylindrical 2170 cells vent through a designed rupture point, which helps, but cell-to-cell propagation inside a tightly packed module is the main hazard.
Handling NMC 811 (2170)
Collecting a Renault Zoe R135 pack
52 kWh, 12 modules, about 291 kg — this is how the Kalamassery, Kerala 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
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
2.96 kg
nickel
19.1 kg
cobalt
2.37 kg
manganese
2.2 kg
copper
9.47 kg
aluminium
7.95 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.
Renault Zoe R135 in Kalamassery, Kerala: common questions
Can I drop off a Renault Zoe R135 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 Renault Zoe R135 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 47% of the pack goes to second life and the rest is refined.
How should a Renault Zoe R135 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 Renault Zoe R135 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.
Renault Zoe R135 at other sites
Other passenger packs at Kalamassery, Kerala
Retiring Renault Zoe R135 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.