Tesla Model Y (4680 Structural) battery recycling in Reno, Nevada
Reno, Nevada does not take whole packs. It receives black mass made from Tesla Model Y (4680 Structural) modules that failed grading, and turns it into battery-grade salts.
Pack value at 80% SOH
3,545 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
45,000 TPA
Hydrometallurgical Refinery
Cities served
7
From Reno, Nevada
Where a Tesla Model Y (4680 Structural) pack goes from Reno, Nevada
- 1
Collected via Dallas, Texas
Whole packs enter the network at Dallas — Texas Reverse Logistics Yard, 2,190 km away, where they are weighed and de-energised.
- 2
Graded at Fremont, California
Modules travel 291 km to Fremont — California Diagnostics Works 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 (8,309 km). Moderate — structural pack bonding limits module harvesting; cell-level grading required.
- 4
Refining at Reno, Nevada
Black mass from failed modules is leached and refined here into battery-grade nickel, cobalt and lithium salts.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Dallas — Texas Reverse Logistics Yard | 2,190 km |
| Nearest grading bench | Fremont — California Diagnostics Works | 291 km |
| Nearest second-life works | Gothenburg — Nordic Second-Life Campus | 8,309 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 Reno, Nevada 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
Reno, Nevada site notes
- Only black mass and cell or cathode scrap are accepted at this site.
- Bulk bags must be sealed, labelled and accompanied by chemistry declarations.
- Deliveries are booked into fixed dock windows at the industrial centre.
- Settlement follows sampling and assay at intake, with results shared with the consignor.
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 refinery is permitted through the Nevada Division of Environmental Protection, with conditions on air emissions, water use and hazardous materials. Inbound feed is managed under the applicable US EPA hazardous or universal waste rules, and shipments follow US DOT hazardous materials regulations.
Tesla Model Y (4680 Structural) in Reno, Nevada: common questions
Can I drop off a Tesla Model Y (4680 Structural) battery at Reno, Nevada?
Reno, Nevada is a hydrometallurgical refinery and does not accept whole packs from customers. Book a collection and the pack enters the network at Dallas, Texas, 2,190 km away.
What happens to Tesla Model Y (4680 Structural) modules after Reno, Nevada?
Collected via Dallas, Texas, then Graded at Fremont, California, then Second life at Gothenburg, Sweden, then Refining 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.
Cities collected by Reno, Nevada
Tesla Model Y (4680 Structural) at other sites
Retiring Tesla Model Y (4680 Structural) packs near Reno, Nevada?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.