Tata Nexon EV Prime battery recycling in Lyon, France
Lyon, France does not take whole packs. It receives black mass made from Tata Nexon EV Prime modules that failed grading, and turns it into battery-grade salts.
Pack value at 80% SOH
967 USD
Hybrid Split
Second-life share
56%
At 80% SOH
Site capacity
23,000 TPA
Hydrometallurgical Refinery
Cities served
3
From Lyon, France
Where a Tata Nexon EV Prime pack goes from Lyon, France
- 1
Collected via Dubai, UAE
Whole packs enter the network at Dubai — Jebel Ali Logistics Yard, 5,003 km away, where they are weighed and de-energised.
- 2
Graded at Stuttgart, Germany
Modules travel 469 km to Stuttgart — Baden-Wurttemberg Grading Works for capacity, resistance and impedance testing across all 12 modules.
- 3
Second life at Zwickau, Saxony
At 80% SOH about 56% of the pack qualifies for reuse and goes to Zwickau — Saxony Second-Life Works (790 km). Excellent — long calendar life makes LFP the preferred feedstock for stationary BESS repurposing.
- 4
Refining at Lyon, France
Black mass from failed modules is leached and refined here into battery-grade lithium salts.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Dubai — Jebel Ali Logistics Yard | 5,003 km |
| Nearest grading bench | Stuttgart — Baden-Wurttemberg Grading Works | 469 km |
| Nearest second-life works | Zwickau — Saxony Second-Life Works | 790 km |
Faster option
Inside the Tata Nexon EV Prime battery
The Tata Nexon EV Prime (2020) carries a 30.2 kWh LFP Prismatic (LiFePO4) pack with 12 modules at 320 V, weighing roughly 224 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 | 95.7% | A — BESS ready | USD 1,576 |
| Year 4 | 92.6% | A — BESS ready | USD 1,526 |
| Year 6 | 89.5% | A — BESS ready | USD 1,476 |
| Year 8 | 86.4% | A — BESS ready | USD 1,417 |
| Year 10 | 83.3% | B — Second life | USD 1,189 |
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 Tata Nexon EV Prime pack
30.2 kWh, 12 modules, about 224 kg — this is how the Lyon, France 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
Lyon, France site notes
- Only black mass and scrap are accepted.
- Cross-border shipments need prior documentation.
- Bulk bags must be sealed and labelled.
- Settlement follows assay at intake.
What this pack yields
lithium
2.24 kg
nickel
0 kg
cobalt
0 kg
manganese
0 kg
copper
6.77 kg
aluminium
8.09 kg
Refining-route estimate at 80% SOH. Measured module health on the bench sets the final split.
Rules in France
EU Battery Regulation (EU) 2023/1542 and the French EPR (REP) system
Regulator: Ministry for Ecological Transition, with ADEME overseeing producer responsibility schemes
The refinery operates under French permitting for classified installations (ICPE) and the EU Battery Regulation (EU) 2023/1542. Waste shipments follow the EU Waste Shipment Regulation.
Tata Nexon EV Prime in Lyon, France: common questions
Can I drop off a Tata Nexon EV Prime battery at Lyon, France?
Lyon, France is a hydrometallurgical refinery and does not accept whole packs from customers. Book a collection and the pack enters the network at Dubai, UAE, 5,003 km away.
What happens to Tata Nexon EV Prime modules after Lyon, France?
Collected via Dubai, UAE, then Graded at Stuttgart, Germany, then Second life at Zwickau, Saxony, then Refining at Lyon, France. At 80% SOH roughly 56% of the pack goes to second life and the rest is refined.
How should a Tata Nexon EV Prime 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 Tata Nexon EV Prime recycling in France?
EU Battery Regulation (EU) 2023/1542 and the French EPR (REP) system, overseen by Ministry for Ecological Transition, with ADEME overseeing producer responsibility schemes. Road transport follows ADR, and cross-border shipments follow the EU Waste Shipment Regulation.
Cities collected by Lyon, France
Tata Nexon EV Prime at other sites
Retiring Tata Nexon EV Prime packs near Lyon, France?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.