What is inside the Switch Mobility EiV 22 Intercity battery pack
The Switch Mobility EiV 22 Intercity carries a 400 kWh pack built from LFP Prismatic (LiFePO4) cells arranged in 28 serviceable modules at a nominal 640 V. Pack mass lands near 2960 kg including the enclosure, cooling plate, contactors and BMS harness.
Because the cells are LFP Prismatic, the recoverable value profile is dominated by lithium, copper and aluminium rather than nickel and cobalt. That decides whether a retired pack is worth repurposing, refining, or both.
| Parameter | Value |
|---|---|
| Chemistry | LFP Prismatic (LiFePO4) |
| Cell format | Prismatic hard case |
| Energy / voltage | 400 kWh · 640 V |
| Modules | 28 |
| Estimated pack mass | 2960 kg |
| On sale since | 2023 (India) |
Step 1 — Removing and shipping a bus pack
Roof- or floor-mounted packs are lifted by crane or gantry with the OEM lifting frame, one string at a time. Retired packs are UN 3480 or UN 3481 dangerous goods, so the pack must be below 30% state of charge and any deformation, swelling or thermal history declared before pickup.
Packs travel as individual heavy crates on flatbed or curtain-side trailers with load restraint rated for the mass. Bus packs are collected per depot and per retirement window, usually a full trailer per visit.
- Confirm crane or gantry access and lifting frame availability
- Isolate each pack string and record its voltage
- Share pack-string serials against the bus fleet number
- Plan collection around depot operating hours
Step 2 — Module-level state of health grading
Each of the 28 modules is tested independently — a whole-pack SOH figure hides the spread that decides second-life eligibility. We run a full capacity cycle, DC internal resistance measurement and impedance spectroscopy.
Our degradation model for the Switch Mobility EiV 22 Intercity shows how value falls with age. Measured results replace these estimates once the pack is on the bench.
| Service year | Modelled SOH | Grade | Residual value |
|---|---|---|---|
| Year 2 | 95.7% | A — BESS ready | USD 20,876 |
| Year 4 | 92.6% | A — BESS ready | USD 20,214 |
| Year 6 | 89.5% | A — BESS ready | USD 19,553 |
| Year 8 | 86.4% | A — BESS ready | USD 18,763 |
| Year 10 | 83.3% | B — Second life | USD 15,748 |
Step 3 — What you actually recover
For modules routed to refining, a pack of this size and chemistry typically yields about 66.7 kg lithium, 0.0 kg nickel, 0.0 kg cobalt and 201.9 kg copper.
At 80% SOH our model sends about 56% of the pack to second life, worth USD 10,311, and credits USD 2,500 for the remainder as black mass. Avoided emissions come to roughly 17,892 kg CO2.
Field note
Step 4 — Where to send it and what paperwork you get
Switch Mobility EiV 22 Intercity packs are received directly at 8 intake sites in its markets, including Chakan, Maharashtra, Sanand, Gujarat, Taloja, Maharashtra, Narela, Delhi. From there, modules move to the nearest grading bench and refinery.
Every consignment closes with a certificate showing quantity processed, recovery percentages achieved and downstream vendor disclosure, in the form needed for CPCB EPR filings under the Battery Waste Management Rules 2022. Fleets retiring several Switch Mobility EiV 22 Intercity units should book one consolidated pickup to cut per-pack cost.