BYD Han EV (85.4 kWh LFP Blade) battery: recycling and second-life options
The BYD Han EV (85.4 kWh LFP Blade) (BYD, 2020-) carries a 85.4 kWh battery pack using LiFePO4 (LFP) Blade chemistry from cell supplier BYD. The pack weighs 540 kg. End-of-life routes split between second-life applications (typically 5-10 more years of grid storage) and full material recycling.
Battery specifications
| Field | Value |
|---|
| Capacity (gross) | 85.4 kWh |
| Chemistry | LiFePO4 (LFP) Blade |
| Cell supplier | BYD |
| Pack weight | 540 kg |
| Manufacturer | BYD |
| Production years | 2020- |
Recoverable materials
A typical BYD Han EV (85.4 kWh LFP Blade) pack contains:
- Lithium: 10.5 kg (carbonate-equivalent ~56 kg)
- Cobalt: 0 (LFP chemistry - no cobalt or nickel)
- Nickel: 0 (LFP chemistry)
- Copper: ~25-50 kg in busbars and current collectors
- Aluminium: ~30-60 kg in cell housings and pack structure
- Steel: pack enclosure
- Graphite: anode material
- Manganese: present in NMC chemistry packs
Second-life value
A BYD Han EV (85.4 kWh LFP Blade) pack typically retains 70-80% capacity at the end of its first automotive life (~8-15 years). At that point it has 5-10 more useful years in lower-cycle applications:
- Grid stabilisation - fleet partnerships (B2U Storage Solutions, Connected Energy)
- Solar self-consumption storage - residential battery walls (some offerings repackage former EV cells)
- Off-grid power - marine, RV, off-grid cabin
- EV charging buffer - used at fast-charge sites to reduce peak grid draw
Typical second-life market value: $4500-9500 USD
Where to sell second-life packs:
- B2U Storage Solutions
- Connected Energy (UK)
- Powervault (UK residential)
- Re-Volv
- Direct sale to integrators via specialist brokers
Full recycling value
If second-life isn't viable (cell damage, capacity below 60%, no buyer), full material recycling routes:
- Recovery value: $400-900 USD
- Recycling cost: $200-600 USD
- Net economics: Often net-neutral or slightly negative - LFP has lower precious-metal content
Major battery recyclers operating in BYD's key markets:
- Li-Cycle (US, Canada, Europe) - hub-and-spoke model
- Redwood Materials (US) - integrated cell-to-cell recycling, supplies recovered cathode material back to major OEMs
- Umicore (Belgium, global) - integrated smelter
- Ecobat - lead-acid + lithium-ion
- BYD closed-loop programme (where available - see take-back URL below)
Manufacturer take-back
BYD sustainability + battery recycling
In the EU, manufacturers are obligated under EU Battery Regulation 2023/1542 (effective 2024) to provide free take-back for EV batteries. In the US, state-level laws vary - California's SB 615 (effective 2026) requires similar manufacturer responsibility.
Compliance and safety
EV batteries are classified as UN3480 / UN3481 (lithium-ion battery) under hazardous-materials transport regulations. Movement requires:
- Class 9 hazmat-certified transporter
- Damaged-pack protocol (typically requires container with non-conductive padding)
- Documentation: Bill of Lading + UN packaging certificate
Cannot be transported on a regular vehicle without certified packaging.
Where this fits in the bigger picture
By 2030, the IEA projects 1.4 million tonnes of EV battery waste annually globally. The BYD Han EV (85.4 kWh LFP Blade) contributes to this stream when retired. With 10.5 kg of lithium per pack, recovering even a fraction returns critical minerals to the supply chain - recovered lithium typically costs 30-50% less in carbon footprint than freshly mined material (NREL ReCell Center data).
Related guides
Sources
- BYD battery sustainability disclosure
- US DOE National Renewable Energy Laboratory ReCell Center
- IEA Global EV Outlook 2024
- EU Battery Regulation 2023/1542
- Cell supplier (BYD) published specifications
- LME spot prices for cobalt, nickel, lithium carbonate
Frequently Asked Questions
How much is a used BYD Han EV (85.4 kWh LFP Blade) battery worth?
Second-life market value (for grid storage, residential battery wall, off-grid use) typically $4500-9500 USD. Full recycling material value $400-900 USD. Almost always more economic to extend useful life via second-life rather than scrap immediately.
What chemistry is the BYD Han EV (85.4 kWh LFP Blade) battery?
LiFePO4 (LFP) Blade, supplied by BYD. The pack weighs 540 kg and stores 85.4 kWh of energy.
How is the BYD Han EV (85.4 kWh LFP Blade) battery recycled?
Major recyclers (Li-Cycle, Redwood Materials, Umicore) dismantle the 540 kg pack, test cells for second-life eligibility (70%+ capacity), then non-viable cells go through hydrometallurgical or pyrometallurgical processing to recover lithium (10.5 kg), with no cobalt or nickel since this is LFP chemistry, copper, and aluminium.
Does BYD take back the BYD Han EV (85.4 kWh LFP Blade) battery?
Yes. See [BYD take-back programme](https://www.bydglobal.com/en/sustainability). Under EU Battery Regulation 2023/1542 (effective 2024), all EU sales include free manufacturer take-back at end-of-life. US take-back is currently voluntary with state-level requirements emerging (California SB 615 effective 2026).
Can I transport an EV battery myself?
No. The BYD Han EV (85.4 kWh LFP Blade) battery is UN3480/UN3481 hazmat-classified. Movement requires a Class 9 certified transporter with proper packaging and Bill of Lading. Damaged packs have additional protocol. Cannot be moved on a regular vehicle.