What is inside the Tata Nexon EV Prime battery pack
The Tata Nexon EV Prime carries a 30.2 kWh pack built from LFP Prismatic (LiFePO4) cells arranged in 12 serviceable modules at a nominal 320 V. Pack mass lands near 223 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 | 30.2 kWh · 320 V |
| Modules | 12 |
| Estimated pack mass | 223 kg |
| On sale since | 2020 (India) |
Step 1 — Removing and shipping a passenger pack
Packs are dropped on a vehicle lift using the OEM procedure and a rated battery table, then isolated at the service disconnect. 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.
One pack per UN-rated pallet box, strapped and restrained, with terminals capped and coolant ports sealed. Dealer and workshop returns are consolidated into full truckloads, typically eight or more packs per run.
- 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
Step 2 — Module-level state of health grading
Each of the 12 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 Tata Nexon EV Prime 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 1,576 |
| Year 4 | 92.6% | A — BESS ready | USD 1,526 |
| Year 6 | 89.5% | A — BESS ready | USD 1,476 |
| Year 8 | 86.4% | A — BESS ready | USD 1,417 |
| Year 10 | 83.3% | B — Second life | USD 1,189 |
Step 3 — What you actually recover
For modules routed to refining, a pack of this size and chemistry typically yields about 5.0 kg lithium, 0.0 kg nickel, 0.0 kg cobalt and 15.2 kg copper.
At 80% SOH our model sends about 56% of the pack to second life, worth USD 778, and credits USD 189 for the remainder as black mass. Avoided emissions come to roughly 1,351 kg CO2.
Field note
Step 4 — Where to send it and what paperwork you get
Tata Nexon EV Prime 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 Tata Nexon EV Prime units should book one consolidated pickup to cut per-pack cost.