Tesla Model Y (4680 Structural) battery recycling in Zaheerabad, Telangana
The Tesla Model Y (4680 Structural) 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
3,545 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 Y (4680 Structural) 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 3 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). Moderate — structural pack bonding limits module harvesting; cell-level grading required.
- 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 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 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
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 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 Y (4680 Structural) in Zaheerabad, Telangana: common questions
Can I drop off a Tesla Model Y (4680 Structural) battery at Zaheerabad, Telangana?
Yes, by appointment. Hyderabad — Zaheerabad Recovery Campus 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 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 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 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 Y (4680 Structural) at other sites
Other passenger packs at Zaheerabad, Telangana
Retiring Tesla Model Y (4680 Structural) 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.