Shell, FAW test immersion-cooled batteries to improve truck performance

Shell and Chinese truck manufacturer FAW Trucks have collaborated to test a battery pack that utilizes an immersion-cooling system to manage heat more effectively, improve vehicle performance and extend battery life, the companies announced. The battery pack uses an electrically insulating fluid to circulate around the battery cells, directly transferring heat away from them during operation.

Maintaining consistent battery temperatures is crucial for commercial vehicles, which often demand high power during acceleration, heavy loads, and charging. By keeping the cells at stable temperatures, the technology aims to enhance the truck's energy efficiency, performance, and potentially prolong battery life.

The testing involved several key areas, such as improved maximum gradability, a 0.8% increase in vehicle-level energy efficiency, and a potential 32% improvement in battery life. These results were obtained from testing the battery pack under specific conditions, including sustained high-power charging and discharging. Additionally, the battery pack underwent standard industry testing and evaluations, with the results verified by the China Automotive Technology and Research Center.

Immersion cooling works by surrounding battery cells with an electrically insulating fluid, which comes into direct contact with the cells to transfer heat away more effectively. Conventional cooling systems typically cool the battery from the bottom, while Shell's immersion fluid surrounds the cells to enhance heat transfer and maintain more consistent temperatures throughout the pack.

The joint testing conducted by Shell and FAW Trucks under specific test conditions will determine if the technology can be implemented in production hybrid commercial vehicles. The battery pack is currently in the validation stage, and its potential production use remains to be determined. The technology is part of Shell's Starship program, which focuses on improving commercial vehicle efficiency and reducing emissions.

The Starship 3.0 Hybrid was developed as a platform for testing hybrid powertrains and battery thermal management under real-world operating conditions. FAW Trucks, a majority-owned subsidiary of China FAW Group, contributed commercial vehicle engineering and development expertise to the partnership.