Volvo XC40 Recharge battery recycling in Fremont, California
Fremont, California is a diagnostics site: Volvo XC40 Recharge packs arrive here from intake yards for module-level capacity, resistance and impedance testing, which decides reuse or refining.
Pack value at 80% SOH
3,656 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
24,000 TPA
Cell Grading & Diagnostics
Cities served
0
From Fremont, California
Where a Volvo XC40 Recharge pack goes from Fremont, California
- 1
Collected via Dallas, Texas
Whole packs enter the network at Dallas — Texas Reverse Logistics Yard, 2,343 km away, where they are weighed and de-energised.
- 2
Module grading at Fremont, California
All 27 modules are tested for capacity, DC resistance and impedance, then assigned grade A to D.
- 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 (8,586 km). Good — grade-A modules above 80% SOH qualify for commercial-scale BESS strings.
- 4
Refined at Reno, Nevada
Remaining modules are shredded to black mass and refined at Reno — Nevada Hydrometallurgy Refinery, 291 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Dallas — Texas Reverse Logistics Yard | 2,343 km |
| Nearest second-life works | Gothenburg — Nordic Second-Life Campus | 8,586 km |
| Nearest refinery | Reno — Nevada Hydrometallurgy Refinery | 291 km |
Faster option
Inside the Volvo XC40 Recharge battery
The Volvo XC40 Recharge (2021) carries a 78 kWh NMC 811 Cylindrical 2170 pack with 27 modules at 400 V, weighing roughly 437 kg. High-nickel cylindrical cells with the strongest hydrometallurgical recovery credit per tonne of black mass.
| Service year | SOH | Grade | Value |
|---|---|---|---|
| Year 2 | 94.9% | A — BESS ready | USD 4,893 |
| Year 4 | 90.6% | A — BESS ready | USD 4,699 |
| Year 6 | 86.3% | A — BESS ready | USD 4,478 |
| Year 8 | 82% | B — Second life | USD 3,893 |
| Year 10 | 77.7% | B — Second life | USD 3,410 |
What the chemistry means here
How it ages
NMC 811 loses capacity through a mix of SEI growth, cathode surface reconstruction and micro-cracking of nickel-rich particles. Resistance climbs faster than in LFP, which matters as much as capacity for second-life duty.
Thermal behaviour
High-nickel NMC cathodes release oxygen as they decompose, so once runaway starts it is fast and energetic. Cylindrical 2170 cells vent through a designed rupture point, which helps, but cell-to-cell propagation inside a tightly packed module is the main hazard.
Handling NMC 811 (2170)
Collecting a Volvo XC40 Recharge pack
78 kWh, 27 modules, about 437 kg — this is how the Fremont, California 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
Fremont, California site notes
- Experimental cells must be declared with chemistry and any known hazards.
- Dismantlers should remove and secure packs before the collection vehicle arrives.
- Include VINs or serial numbers to support California record-keeping.
- Damaged packs require advance notice and ship under separate paperwork.
What this pack yields
lithium
4.44 kg
nickel
28.66 kg
cobalt
3.55 kg
manganese
3.3 kg
copper
14.2 kg
aluminium
11.92 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 works operates under California's demanding hazardous-waste regime, overseen by the Department of Toxic Substances Control, alongside local permitting. California has also legislated towards producer responsibility for EV batteries, so records are kept in a form that supports evolving requirements. Transport follows US DOT hazardous materials rules.
Volvo XC40 Recharge in Fremont, California: common questions
Can I drop off a Volvo XC40 Recharge battery at Fremont, California?
Fremont, California is a cell grading & diagnostics and does not accept whole packs from customers. Book a collection and the pack enters the network at Dallas, Texas, 2,343 km away.
What happens to Volvo XC40 Recharge modules after Fremont, California?
Collected via Dallas, Texas, then Module grading at Fremont, California, 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 Volvo XC40 Recharge 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 Volvo XC40 Recharge 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.
Volvo XC40 Recharge at other sites
Other passenger packs at Fremont, California
Retiring Volvo XC40 Recharge packs near Fremont, California?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.