Shell Lubricants and FAW Trucks have completed vehicle validation of a jointly developed battery pack using immersion cooling technology for commercial vehicle applications.

The battery pack was integrated into the Shell Starship 3.0 Hybrid concept truck, where it underwent testing under commercial vehicle operating conditions, including sustained high-power charging and discharging. The technology is being evaluated for potential use in future FAW Trucks hybrid commercial vehicles.

The battery pack uses an electrically insulating immersion cooling fluid that surrounds the battery cells. According to Shell, the approach allows the fluid to make direct contact with the cells across a larger surface area than conventional cooling systems, helping transfer heat and maintain more consistent cell temperatures.

Initial vehicle validation indicated a potential 0.8% improvement in vehicle-level energy efficiency, along with up to a 98% increase in maximum gradability and a potential battery life improvement of up to 32%. Shell noted that final performance data will be released after validation is complete.

The battery pack has also completed industry-standard testing, with independent verification by the China Automotive Technology and Research Center.

“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 Trucks. “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.”

Shell and FAW Trucks developed the battery pack as part of the Shell Starship Hybrid technology demonstration program. The platform is intended to evaluate technologies related to hybrid powertrains, lubrication and battery thermal management.

The latest validation results and the Shell Starship Hybrid will be displayed at the FAW Trucks booth during IAA Transportation 2026 in Hannover, Germany, September 14-19.