Shell, FAW partner on better, safer electric semi truck batteries

The Starship 3.0 concept truck has been busy of late, testing a battery pack that uses an immersion-cooling system to manage battery heat, improve range performance, and enhance the durability of electric semi truck batteries.

Co-developed by Chinese truck brand FAW and Shell oil’s chemical division, the new battery pack surrounds the truck’s battery cells in an electrically insulating immersion cooling fluid, enabling more effective heat management than conventional EV battery cooling.

The batteries, fitted to the Starship Hybrid concept semi truck shown here, has reportedly completed industry-standard testing for on-road certification, and has been undergoing FAW validation under its typical demanding commercial vehicle operating conditions – conditions that include sustained high-power charging, and rapid discharging.

“Battery thermal management is becoming increasingly important as commercial vehicles demand higher power, greater efficiency and faster charging capabilities,” said Wang Jianyu, President of Commercial Vehicle Development Institute of FAW. ” By working with Shell, we have combined FAW TRUCKS’ expertise in commercial vehicle engineering with Shell’s advanced immersion cooling technology to develop a solution for these evolving challenges. Validation on the Starship Hybrid brings us closer to commercial application, with the potential to enhance performance, durability and safety for the next generation of hybrid commercial vehicles.”

The initial vehicle tests are showing some pretty compelling numbers, with Shell and FAW claiming their immersion-cooled batteries delivered up to a 98% increase in maximum gradability (the truck’s ability to climb steep hills under load and a critical metric for power output), a 0.8% improvement in energy efficiency and the potential for up to 32% longer battery life compared with the conventional cooling setup.

The latest validation progress, along with the Starship concept, itself, will be showcased at the FAW TRUCKS booth during IAA Transportation 2026 in Hannover, Germany all this week, alongside a sample of the immersion batteries.

SOURCE | IMAGES: Shell; via Freightwaves.