Shell Lubricants has announced a major breakthrough in electric vehicle (EV) technology with the development of a high-performance thermal management fluid designed to significantly reduce charging times while maintaining battery safety, stability, and lifespan.
In collaboration with UK-based automotive innovation company RML Group, Shell created a 34 kWh battery pack using its EV-Plus Thermal Fluid, formulated with proprietary Shell Gas-to-Liquid (GTL) Technology. The system demonstrated charging from 10 percent to 80 percent in under 10 minutes — a milestone that could transform battery electric vehicle (BEV) adoption globally.
Fast Charging Without Compromising Battery Safety
The new Shell EV-Plus Thermal Fluid mitigates thermal stresses, enabling batteries to handle higher charging currents safely. In a lightweight, aerodynamic vehicle operating at 10 km/kWh efficiency, this technology could deliver charging rates equivalent to 24 km of driving range per minute—far surpassing the current industry average of 5 km per minute.
Advanced Cooling Technology for Next-Gen EV Batteries
Shell’s EV-Plus Thermal Fluids are:
Electrically non-conductive, ensuring safe use inside battery packs.
Designed to maximize heat transfer by filling all interstitial spaces between cells.
Capable of handling the intense heat generated during ultra-fast charging, ensuring uniform temperature control.
Proven to provide enhanced protection against thermal runaway events while enabling simpler, more compact, and cost-effective battery pack designs.
Industry Impact and Global Adoption
Jason Wong, Global Executive Vice President, Shell Lubricants, highlighted the announcement on World EV Day, saying:
“Shell EV-Plus Thermal Fluids can significantly improve battery thermal performance, paving the way for faster charging, enhanced safety, and greater convenience—supporting the widespread adoption of EVs demanded by global legislation.”
Robert Mainwaring, Shell’s lead engineer on the project, added:
“Our goal was to prove that Shell EV-Plus Thermal Fluids could support rapid charging without compromising cell integrity or lifespan. This innovation will accelerate the shift toward more sustainable, efficient, and cost-effective BEVs.”
Addressing EV Consumer Concerns
Global BEV sales grew 14 percent in 2024 compared to 2023, with EVs in Europe and the U.S. often driven further annually than internal combustion engine (ICE) vehicles. However, range anxiety and lack of charging infrastructure remain top concerns, cited by over 44 percent of non-EV drivers in Europe, the U.S., and China. By drastically reducing charging times, Shell’s breakthrough directly addresses these barriers to adoption.
Driving the Future of Electric Mobility
Building on its expertise in transformer oils, GTL technology, and immersion cooling for data centers, Shell is positioning itself as a critical enabler of next-generation EV technology. The new thermal management fluid offers a scalable pathway to faster charging EVs with longer range, safer operation, and reduced complexity — advancing the future of sustainable mobility.
Faheema P