Tesla Model Y (4680 Structural) battery recycling in Bhiwadi, Rajasthan
Bhiwadi, Rajasthan is a diagnostics site: Tesla Model Y (4680 Structural) packs arrive here from intake yards for module-level capacity, resistance and impedance testing, which decides reuse or refining.
Pack value at 80% SOH
3,545 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
9,000 TPA
Cell Grading & Diagnostics
Cities served
0
From Bhiwadi, Rajasthan
Where a Tesla Model Y (4680 Structural) pack goes from Bhiwadi, Rajasthan
- 1
Collected via Narela, Delhi
Whole packs enter the network at Delhi — Narela Collection Yard, 75 km away, where they are weighed and de-energised.
- 2
Module grading at Bhiwadi, Rajasthan
All 3 modules are tested for capacity, DC resistance and impedance, then assigned grade A to D.
- 3
Second life at Mandi Gobindgarh, Punjab
At 80% SOH about 47% of the pack qualifies for reuse and goes to Ludhiana — Mandi Gobindgarh Second-Life Works (315 km). Moderate — structural pack bonding limits module harvesting; cell-level grading required.
- 4
Refined at Haldia, West Bengal
Remaining modules are shredded to black mass and refined at Kolkata — Haldia Refining Works, 1,321 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Delhi — Narela Collection Yard | 75 km |
| Nearest second-life works | Ludhiana — Mandi Gobindgarh Second-Life Works | 315 km |
| Nearest refinery | Kolkata — Haldia Refining Works | 1,321 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 Bhiwadi, Rajasthan 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
Bhiwadi, Rajasthan site notes
- Bus and heavy truck packs are better routed to an integrated campus with lifting equipment.
- Give module counts and formats when booking so the right fixtures are prepared before arrival.
- Loads from Haryana should carry correct interstate documentation to avoid delays at the gate.
- Declare damaged items in advance; the site has limited quarantine space.
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 station operates under Rajasthan State Pollution Control Board consent in a RIICO industrial area and grades material for producers operating under the Battery Waste Management Rules 2022. Because many consignments cross the state border with Haryana, interstate transport paperwork is checked at intake.
Tesla Model Y (4680 Structural) in Bhiwadi, Rajasthan: common questions
Can I drop off a Tesla Model Y (4680 Structural) battery at Bhiwadi, Rajasthan?
Bhiwadi, Rajasthan is a cell grading & diagnostics and does not accept whole packs from customers. Book a collection and the pack enters the network at Narela, Delhi, 75 km away.
What happens to Tesla Model Y (4680 Structural) modules after Bhiwadi, Rajasthan?
Collected via Narela, Delhi, then Module grading at Bhiwadi, Rajasthan, then Second life at Mandi Gobindgarh, Punjab, then Refined at Haldia, West Bengal. 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 Bhiwadi, Rajasthan
Retiring Tesla Model Y (4680 Structural) packs near Bhiwadi, Rajasthan?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.