Tesla Model S Plaid battery recycling in Zaheerabad, Telangana
The Tesla Model S Plaid is not sold in India, so packs reach Zaheerabad, Telangana 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
4,366 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
17,000 TPA
Integrated Recovery Campus
Cities served
0
From Zaheerabad, Telangana
Where a Tesla Model S Plaid pack goes from Zaheerabad, Telangana
- 1
Intake at Zaheerabad, Telangana
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 Hosur, Tamil Nadu
Modules travel 550 km to Bengaluru — Hosur Diagnostics Centre for capacity, resistance and impedance testing across all 16 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 (387 km). Selective — only low-swell pouch stacks above 82% SOH are cleared for repurposing.
- 4
Refined at Atchutapuram, Andhra Pradesh
Remaining modules are shredded to black mass and refined at Visakhapatnam — Atchutapuram Refinery, 558 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest grading bench | Bengaluru — Hosur Diagnostics Centre | 550 km |
| Nearest second-life works | Nagpur — Butibori Second-Life Works | 387 km |
| Nearest refinery | Visakhapatnam — Atchutapuram Refinery | 558 km |
Faster option
Inside the Tesla Model S Plaid battery
The Tesla Model S Plaid (2021) carries a 100 kWh NCA Pouch pack with 16 modules at 400 V, weighing roughly 540 kg. Premium nickel-cobalt pouch stacks with the highest recovery credit and the strictest safety handling class.
| Service year | SOH | Grade | Value |
|---|---|---|---|
| Year 2 | 95.3% | A — BESS ready | USD 5,456 |
| Year 4 | 91% | A — BESS ready | USD 5,248 |
| Year 6 | 86.7% | A — BESS ready | USD 5,039 |
| Year 8 | 82.4% | B — Second life | USD 4,580 |
| Year 10 | 78.1% | B — Second life | USD 4,220 |
What the chemistry means here
How it ages
NCA can deliver long life when it is kept in a moderate state-of-charge window, but it is sensitive to high voltage and heat. Swelling from gas generation is a common retirement signal in pouch formats.
Thermal behaviour
NCA shares the oxygen-release behaviour of high-nickel cathodes and is generally considered among the more reactive EV chemistries. Pouch cells have no rigid can, so mechanical damage and swelling translate quickly into safety risk.
Handling NCA Pouch
Collecting a Tesla Model S Plaid pack
100 kWh, 16 modules, about 540 kg — this is how the Zaheerabad, Telangana 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
Zaheerabad, Telangana site notes
- Bus packs require advance notice so lifting equipment and a trained crew are scheduled.
- Share pack drawings or architecture notes for unfamiliar commercial formats before collection.
- Hyderabad fleet depots can book recurring scheduled collections.
- Damaged units are received in a dedicated quarantine building away from the main floor.
What this pack yields
lithium
5.33 kg
nickel
38.87 kg
cobalt
6.43 kg
manganese
0.63 kg
copper
20.22 kg
aluminium
12.85 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 operates under Telangana State Pollution Control Board consent within the Zaheerabad NIMZ, with conditions covering shredding, dust control and fire safety. It issues recovery evidence for producers registered under the Battery Waste Management Rules 2022.
Tesla Model S Plaid in Zaheerabad, Telangana: common questions
Can I drop off a Tesla Model S Plaid battery at Zaheerabad, Telangana?
Yes, by appointment. Hyderabad — Zaheerabad Recovery Campus accepts whole Tesla Model S Plaid packs; book a collection or a drop-off slot so the site can prepare packaging and paperwork.
What happens to Tesla Model S Plaid modules after Zaheerabad, Telangana?
Intake at Zaheerabad, Telangana, then Graded at Hosur, Tamil Nadu, then Second life at Butibori, Maharashtra, then Refined at Atchutapuram, Andhra Pradesh. At 80% SOH roughly 47% of the pack goes to second life and the rest is refined.
How should a Tesla Model S Plaid 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 Tesla Model S Plaid 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.
Tesla Model S Plaid at other sites
Other passenger packs at Zaheerabad, Telangana
Retiring Tesla Model S Plaid packs near Zaheerabad, Telangana?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.