Volvo XC40 Recharge battery recycling in Warsaw, Mazovia
Warsaw, Mazovia 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
17,000 TPA
Cell Grading & Diagnostics
Cities served
0
From Warsaw, Mazovia
Where a Volvo XC40 Recharge pack goes from Warsaw, Mazovia
- 1
Collected via Dubai, UAE
Whole packs enter the network at Dubai — Jebel Ali Logistics Yard, 4,157 km away, where they are weighed and de-energised.
- 2
Module grading at Warsaw, Mazovia
All 27 modules are tested for capacity, DC resistance and impedance, then assigned grade A to D.
- 3
Second life at Zwickau, Saxony
At 80% SOH about 47% of the pack qualifies for reuse and goes to Zwickau — Saxony Second-Life Works (613 km). Good — grade-A modules above 80% SOH qualify for commercial-scale BESS strings.
- 4
Refined at Rotterdam, South Holland
Remaining modules are shredded to black mass and refined at Rotterdam — Maasvlakte Refining Works, 1,128 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Dubai — Jebel Ali Logistics Yard | 4,157 km |
| Nearest second-life works | Zwickau — Saxony Second-Life Works | 613 km |
| Nearest refinery | Rotterdam — Maasvlakte Refining Works | 1,128 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 Warsaw, Mazovia 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
Warsaw, Mazovia site notes
- Cross-border loads need appropriate shipment documents.
- Bus operators should book in advance for large packs.
- Send a serial list with each load.
- Declare damaged packs before collection.
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 Poland
EU Battery Regulation (EU) 2023/1542 and the Polish Act on Batteries and Accumulators
Regulator: Chief Inspectorate of Environmental Protection (GIOS), with the BDO waste database
The centre operates under Polish environmental permits and the EU Battery Regulation (EU) 2023/1542. Transport follows ADR dangerous-goods rules, and cross-border movements follow EU waste shipment requirements.
Volvo XC40 Recharge in Warsaw, Mazovia: common questions
Can I drop off a Volvo XC40 Recharge battery at Warsaw, Mazovia?
Warsaw, Mazovia is a cell grading & diagnostics and does not accept whole packs from customers. Book a collection and the pack enters the network at Dubai, UAE, 4,157 km away.
What happens to Volvo XC40 Recharge modules after Warsaw, Mazovia?
Collected via Dubai, UAE, then Module grading at Warsaw, Mazovia, then Second life at Zwickau, Saxony, then Refined at Rotterdam, South Holland. 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 Poland?
EU Battery Regulation (EU) 2023/1542 and the Polish Act on Batteries and Accumulators, overseen by Chief Inspectorate of Environmental Protection (GIOS), with the BDO waste database. Road transport follows ADR, and cross-border shipments follow the EU Waste Shipment Regulation.
Volvo XC40 Recharge at other sites
Retiring Volvo XC40 Recharge packs near Warsaw, Mazovia?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.