QAZAQ GREEN.  Shell has successfully developed a new thermal management fluid that enables electric vehicle batteries to charge from 10% to 80% capacity in under 10 minutes, the company announced today.

The breakthrough was demonstrated through a collaboration with UK automotive innovation company RML Group, using a 34 kWh battery pack equipped with Shell's EV-Plus Thermal Fluid technology. The fluid incorporates Shell's proprietary Gas-to-Liquid (GTL) technology and significantly reduces thermal stress during charging, allowing battery cells to tolerate much higher charging currents.

According to Shell's testing, the technology could enable charging rates of up to 24 kilometers of range per minute in a lightweight, aerodynamic vehicle with 10 km/kWh efficiency — nearly five times faster than the typical 5 km per minute achieved by many current electric vehicles.

The thermal fluid is electrically non-conductive and works by filling interstitial spaces within battery packs to maximize direct contact with individual cells. This immersion cooling approach manages the high heat levels generated during rapid charging while maintaining temperature consistency across the entire battery pack.

"The advanced thermal management technology showcases compact battery pack designs that are cost-effective and less complex," said Robert Mainwaring, Shell's lead engineer on the project.

The development addresses key consumer concerns about electric vehicle adoption. Shell's recent survey data shows that over 44% of non-EV drivers in Europe, USA and China cite range anxiety or lack of charging infrastructure as barriers to adoption, despite BEV sales growing 14% in 2024.

The immersion cooling technology enables smaller, lighter battery packs while using existing charging network infrastructure. Shell plans to showcase the EV-Plus thermal fluids at The Battery Show North America in Detroit from October 6-9, 2025.