Tesla Model S Plaid battery recycling in Lyon, France
Lyon, France does not take whole packs. It receives black mass made from Tesla Model S Plaid modules that failed grading, and turns it into battery-grade salts.
Pack value at 80% SOH
4,366 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
23,000 TPA
Hydrometallurgical Refinery
Cities served
3
From Lyon, France
Where a Tesla Model S Plaid 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 16 modules.
- 3
Second life at Zwickau, Saxony
At 80% SOH about 47% of the pack qualifies for reuse and goes to Zwickau — Saxony Second-Life Works (790 km). Selective — only low-swell pouch stacks above 82% SOH are cleared for repurposing.
- 4
Refining at Lyon, France
Black mass from failed modules is leached and refined here into battery-grade nickel, cobalt and 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 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 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
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 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.
Tesla Model S Plaid in Lyon, France: common questions
Can I drop off a Tesla Model S Plaid 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 Tesla Model S Plaid 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 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 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
Tesla Model S Plaid at other sites
Retiring Tesla Model S Plaid 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.