Shell and FAW TRUCKS Validate Immersion-Cooling Battery for Heavy-Duty Transport
A new thermal management system tested on a hybrid concept truck shows significant gains in battery life and gradability.
Shell Lubricants and FAW TRUCKS have developed and validated a battery pack featuring an immersion-cooling system designed for commercial vehicles. The technology aims to solve critical thermal bottlenecks in heavy-duty electrification to improve energy efficiency and vehicle durability.
Tested on the Shell Starship 3.0 Hybrid concept truck, the system replaces conventional bottom-cooling plates with an electrically insulating fluid that completely surrounds the battery cells. This method allows for more effective heat transfer across the cell surface. According to validation results verified by the China Automotive Technology and Research Center, the system delivered a 0.8% improvement in vehicle-level energy efficiency and a substantial increase in maximum gradability of up to 98%. Furthermore, the partnership indicates that this immersion-cooling approach could potentially extend battery life by as much as 32%.
The Engineering Context
The project is a core component of the Shell Starship program, which serves as a technology demonstration platform focused on reducing emissions and increasing the efficiency of commercial transport. The development was a collaborative effort: FAW TRUCKS, a subsidiary of China FAW Group, provided the necessary engineering expertise, while Shell contributed the specialized thermal-management fluid technology. The results were officially showcased at IAA Transportation 2026 in Hannover, Germany, beginning September 14.
Why Thermal Management Matters
Effective heat dissipation is one of the primary technical hurdles for electric and hybrid semi-trucks. These vehicles experience extreme battery stress during high-power charging, rapid acceleration, and the hauling of heavy loads. Conventional cooling methods often struggle to maintain optimal temperatures under these conditions, which can lead to degraded battery health and limited power output. By immersing cells in a dielectric fluid, manufacturers can potentially increase charging speeds and power delivery without sacrificing the longevity of the battery pack.
The Path Forward
While the current results are based on the Starship 3.0 Hybrid concept vehicle rather than a production fleet, the validation marks a step toward commercial viability. The industry will now be watching to see if these performance gains can be scaled from a concept platform to mass-produced heavy-duty commercial vehicles. If successful, this shift toward immersion cooling could redefine the operational limits of heavy-duty electric transport, allowing for steeper climbs and longer service intervals between battery replacements.