Ford Mustang Mach-E (91 kWh) battery: recycling and second-life options
The Ford Mustang Mach-E (91 kWh) (Ford, 2021-) carries a 91 kWh battery pack using NMC chemistry from cell supplier SK On. The pack weighs 530 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) | 91 kWh |
| Chemistry | NMC |
| Cell supplier | SK On |
| Pack weight | 530 kg |
| Manufacturer | Ford |
| Production years | 2021- |
Recoverable materials
A typical Ford Mustang Mach-E (91 kWh) pack contains:
- Lithium: 11 kg (carbonate-equivalent ~59 kg)
- Cobalt: 7 kg
- Nickel: 78 kg
- 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 Ford Mustang Mach-E (91 kWh) 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: $6000-12000 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: $1100-2000 USD
- Recycling cost: $0-400 USD
- Net economics: Generally net-positive - manufacturer often sees a credit when delivering NMC/NCA packs
Major battery recyclers operating in Ford'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 Ford
- Umicore (Belgium, global) - integrated smelter
- Ecobat - lead-acid + lithium-ion
- Ford closed-loop programme (where available - see take-back URL below)
Manufacturer take-back
Ford 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 Ford Mustang Mach-E (91 kWh) contributes to this stream when retired. With 11 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
- Ford battery sustainability disclosure
- US DOE National Renewable Energy Laboratory ReCell Center
- IEA Global EV Outlook 2024
- EU Battery Regulation 2023/1542
- Cell supplier (SK On) published specifications
- LME spot prices for cobalt, nickel, lithium carbonate
Frequently Asked Questions
How much is a used Ford Mustang Mach-E (91 kWh) battery worth?
Second-life market value (for grid storage, residential battery wall, off-grid use) typically $6000-12000 USD. Full recycling material value $1100-2000 USD. Almost always more economic to extend useful life via second-life rather than scrap immediately.
What chemistry is the Ford Mustang Mach-E (91 kWh) battery?
NMC, supplied by SK On. The pack weighs 530 kg and stores 91 kWh of energy.
How is the Ford Mustang Mach-E (91 kWh) battery recycled?
Major recyclers (Li-Cycle, Redwood Materials, Umicore) dismantle the 530 kg pack, test cells for second-life eligibility (70%+ capacity), then non-viable cells go through hydrometallurgical or pyrometallurgical processing to recover lithium (11 kg), cobalt (7 kg), nickel (78 kg), copper, and aluminium.
Does Ford take back the Ford Mustang Mach-E (91 kWh) battery?
Yes. See [Ford take-back programme](https://corporate.ford.com/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 Ford Mustang Mach-E (91 kWh) 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.