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Shell concept car with recycled carbon fiber

News International-French

27 Apr 2016

Could ultra-efficient cars like the new Shell concept car help address some of the world’s urban transport challenges?

It’s a city car that uses a third less energy in its lifetime than a typical city car, designed with the kind of attention to weight reduction and aerodynamics found in Formula One™ racing. This ultra-light prototype’s low-cost, low-carbon construction demonstrates a way to help keep increasingly crowded cities moving, while minimising energy use and emissions.

“You could build this car and drive it for around 100,000 kilometres before consuming the same energy it takes to make a typical SUV,” says engineer Bob Mainwaring, Shell’s Technology Manager for Innovation, who is leading the project.

By the middle of this century three-quarters of the world’s population is expected to live in cities, while the number of cars on the road could double. Cars powered by electricity, low-carbon biofuels or even hydrogen could play a growing role in road transport of the future. But much more efficient combustion engines using petrol or diesel are needed to reduce carbon dioxide (CO2) emissions and air pollution in the shorter term.

An inside view of the Shell concept car, looking towards the dashboard.
“We wanted to see what kind of an impact we could have if we really pushed the boundaries of what combustion engine cars can do today,” says Mainwaring.

F1™ designer Gordon Murray, engine experts Geo Technology and Shell scientists have worked closely together to co-engineer the car’s body, engine and lubricant to minimise fuel use and CO2 emissions. The result is a concept car that uses significantly less energy from its manufacture to the end of its life. 

The car has a top speed of 110 kilometres per hour (km/h) – more than enough for a day trip away from the city – but performs best at 50-70km/h. Independent tests suggest that it can drive 100km on just 2.6 litres of petrol at a steady 70km/h. In tests, it produced at least a quarter fewer CO2 emissions than typical petrol-powered city and hybrid cars. The car’s body is made with recycled carbon fibre. This helps to reduce its overall weight to 550 kilograms, while cutting the energy used in manufacturing by up to 45% compared to a city car available today.

Wing mirrors have been replaced with tiny digital cameras that relay the view of the road behind through screens inside, while new wheel-arch covers further reduce drag.

On the inside, Geo Technology improved the efficiency of an engine already found in some city cars that uses a diamond-like carbon coating to help minimise friction, while Shell scientists developed a special lubricant.

“The lower weight and the aerodynamic improvement has been a significant factor in increasing the efficiency. So has the engine lubricant collaboration between Shell and Geo Technology. By working together we’ve achieved far more than we could have done on our own,” said Matt Brewerton, the lead project design engineer at GMD.