Shell introduces a BEV powertrain single-fluid thermal system

Shell has unveiled a significant breakthrough in battery electric vehicle (BEV) thermal management with its new EV-Plus Thermal Fluid, which is capable of cooling all major BEV powertrain components through a single-circuit, single-fluid system.

Developed in collaboration with engineering consultancy HORIBA MIRA, the innovation demonstrates that Shell’s dielectric fluid can replace the multiple cooling loops typically required for batteries, electric motors, and power electronics. Extensive testing across simulated real-world environments—from extreme Arctic temperatures to intense desert heat—confirmed the fluid’s ability to deliver consistent thermal control and maintain performance.

Jason Wong, Global Executive Vice President of Shell Lubricants, said the unified cooling approach has the potential to simplify BEV manufacturing, lowering system complexity, reducing component count and overall vehicle weight, and enabling cost efficiencies while supporting faster charging capabilities.

Shell’s EV-Plus Thermal Fluid is formulated using the company’s proprietary PurePlus Technology, a gas-to-liquid (GTL) process that creates a 99.5% pure base oil with high dielectric strength and excellent thermal conductivity. The fluid supports direct battery-cell immersion, enabling ultra-fast charging from 10% to 80% in under 10 minutes, and can also function effectively as an indirect coolant for other powertrain components.

According to Robert Mainwaring, Shell’s lead engineer on the project, the fluid is compatible with existing vehicle hardware, allowing it to replace traditional glycol-based coolants and positioning it as “a game-changer” for BEV design.

Dr. David Bridge, Chief Engineer for Thermal Systems at HORIBA MIRA, described the breakthrough as a “critical enabler” for faster charging, enhanced safety, and longer component life—representing a significant step forward on the path to fully electrified mobility.

The detailed article is published by https://www.evinfrastructurenews.com/ can be accessed from https://www.evinfrastructurenews.com/ev-technology/shell-announces-all-in-one-ev-powertrain-and-battery-coolant-for-economic-high-speed-charging