Tesla Model Y (4680 Structural) battery recycling in Dallas, Texas
Dallas — Texas Reverse Logistics Yard takes whole Tesla Model Y (4680 Structural) packs straight from fleets, dealers and workshops. Packs are weighed, de-energised and logged here before modules move on for grading or refining.
Pack value at 80% SOH
3,545 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
19,000 TPA
Reverse Logistics Yard
Cities served
0
From Dallas, Texas
Where a Tesla Model Y (4680 Structural) pack goes from Dallas, Texas
- 1
Intake at Dallas, Texas
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 Atlanta, Georgia
Modules travel 1,158 km to Atlanta — Georgia Grading Centre for capacity, resistance and impedance testing across all 3 modules.
- 3
Second life at Gothenburg, Sweden
At 80% SOH about 47% of the pack qualifies for reuse and goes to Gothenburg — Nordic Second-Life Campus (7,978 km). Moderate — structural pack bonding limits module harvesting; cell-level grading required.
- 4
Refined at Reno, Nevada
Remaining modules are shredded to black mass and refined at Reno — Nevada Hydrometallurgy Refinery, 2,190 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest grading bench | Atlanta — Georgia Grading Centre | 1,158 km |
| Nearest second-life works | Gothenburg — Nordic Second-Life Campus | 7,978 km |
| Nearest refinery | Reno — Nevada Hydrometallurgy Refinery | 2,190 km |
Inside the Tesla Model Y (4680 Structural) battery
The Tesla Model Y (4680 Structural) (2022) carries a 82 kWh NMC 811 Cylindrical 4680 pack with 3 modules at 355 V, weighing roughly 418 kg. Structural tabless format requiring specialised disassembly cells. High nickel yields offset elevated processing cost.
| Service year | SOH | Grade | Value |
|---|---|---|---|
| Year 2 | 94.2% | A — BESS ready | USD 4,607 |
| Year 4 | 89.9% | A — BESS ready | USD 4,425 |
| Year 6 | 85.6% | A — BESS ready | USD 4,162 |
| Year 8 | 81.3% | B — Second life | USD 3,674 |
| Year 10 | 77% | B — Second life | USD 3,281 |
What the chemistry means here
How it ages
Fade mechanisms mirror other NMC 811 cells. The tabless design lowers internal resistance and heat generation, which can slow resistance growth relative to older cylindrical formats.
Thermal behaviour
4680 cells carry the same high-nickel chemistry as 2170s but in a larger can with more energy per cell, so a single failing cell releases more heat. Structural packs also make it harder to isolate an individual failing cell during handling.
Handling NMC 811 (4680)
Collecting a Tesla Model Y (4680 Structural) pack
82 kWh, 3 modules, about 418 kg — this is how the Dallas, Texas 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
Dallas, Texas site notes
- Summer pickups are scheduled to minimise the time packs spend in hot trailers.
- Declare state of charge; high-SOC packs are discharged before they are forwarded.
- Fleet operators can set up recurring depot collections.
- Damaged units are isolated in dedicated containment on arrival.
What this pack yields
lithium
4.49 kg
nickel
29.01 kg
cobalt
2.91 kg
manganese
3.03 kg
copper
12.26 kg
aluminium
14.08 kg
Refining-route estimate at 80% SOH. Measured module health on the bench sets the final split.
Rules in United States
EPA universal waste rules, DOT hazardous materials regulations and state programmes
Regulator: EPA, DOT PHMSA and state environmental agencies
The yard operates under Texas Commission on Environmental Quality requirements for storing and handling waste batteries, applying the US EPA universal waste framework where applicable. Transport follows US DOT hazardous materials regulations.
Tesla Model Y (4680 Structural) in Dallas, Texas: common questions
Can I drop off a Tesla Model Y (4680 Structural) battery at Dallas, Texas?
Yes, by appointment. Dallas — Texas Reverse Logistics Yard accepts whole Tesla Model Y (4680 Structural) packs; book a collection or a drop-off slot so the site can prepare packaging and paperwork.
What happens to Tesla Model Y (4680 Structural) modules after Dallas, Texas?
Intake at Dallas, Texas, then Graded at Atlanta, Georgia, then Second life at Gothenburg, Sweden, then Refined at Reno, Nevada. At 80% SOH roughly 47% of the pack goes to second life and the rest is refined.
How should a Tesla Model Y (4680 Structural) 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 Y (4680 Structural) recycling in United States?
EPA universal waste rules, DOT hazardous materials regulations and state programmes, overseen by EPA, DOT PHMSA and state environmental agencies. Shipments follow DOT PHMSA 49 CFR requirements, with damaged or defective batteries under stricter special permits and packaging.
Tesla Model Y (4680 Structural) at other sites
Retiring Tesla Model Y (4680 Structural) packs near Dallas, Texas?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.