Shell Unveils Starship 3.0: A Leap Toward Sustainable Trucking

BIRMINGHAM, AL — Shell recently unveiled the third iteration of its groundbreaking Starship truck, showcasing its strides in sustainable transportation. The truck, nicknamed Starship 3.0, serves as a testing platform for advanced technology, focusing on fuel efficiency, emissions reduction, and reduced operational costs. Launched at a special event in Birmingham, Alabama, the truck was presented as a transformative model in the trucking industry, merging Shell’s expertise in lubricants and fuels with innovations from industry partners.

A Testbed for the Future of Trucking

Heather Duffy, a marketing specialist with the Shell Starship program, explained that the initiative began as an experimental program in 2018 to explore readily available, eco-friendly technologies for fleet managers. “The Starship program started as a test program for fleets to learn how they can reduce their carbon emissions and total cost of ownership,” Duffy said. The early versions tested the impact of Shell’s low-viscosity engine oils, which were launched in 2016. Each new version has provided invaluable insights into fuel efficiency, guiding fleets toward greener operations.

Transition to Natural Gas with the Cummins X15N Engine

This year’s model, Starship 3.0, represents a significant shift, moving from diesel engines to natural gas. The truck is now equipped with the Cummins X15N natural gas engine, capable of running on both compressed and renewable natural gas (RNG). The engine has been optimized for fuel economy while retaining the necessary torque and towing capacity to handle heavy loads—a common challenge for previous natural gas engines, which struggled with mountainous terrain and heavy payloads.

Duffy reported an impressive milestone: “We were able to achieve nine miles per gallon fully loaded at 80,000 pounds.” This figure is a notable benchmark for fuel efficiency, especially for natural gas engines, which typically operate at higher temperatures than diesel engines. The impressive efficiency levels were achieved across various terrains in California, proving the truck’s reliability for long hauls.

Collaborations with Industry Giants

The Starship program benefits from collaborations with companies like Cummins and Bridgestone. These partnerships have allowed Shell to experiment with different technological advancements, such as low-rolling-resistance tires from Bridgestone, which contribute significantly to fuel savings. “These are relatively small changes that can make a big difference in fleet operations,” Duffy noted. Innovations like low-viscosity engine oils and advanced tire technology are easily adoptable by fleets, helping them reduce costs while becoming more environmentally conscious.

Natural Gas as a Viable Alternative, But Not Without Challenges

The use of natural gas in heavy-duty vehicles is not without obstacles. Kevin Otto from the North American Council for Freight Efficiency (NACFE) highlighted the significance of “freight ton efficiency”—a measure of how much fuel is used per ton of cargo transported over a certain distance. Otto explained that Starship 3.0’s switch to a 15-liter natural gas engine from the previous 12-liter version demonstrated improved freight ton efficiency due to the truck’s ability to handle heavy loads without sacrificing fuel economy.

Mike Ro, Executive Director of NACFE, noted that natural gas remains a promising option, particularly for long-haul trucking. According to Ro, natural gas offers unique benefits, especially with advancements in RNG. “We started scaling natural gas about ten years ago, but diesel prices dropped, and the interest waned. Now, we’re looking at it again,” Ro said. While natural gas engines may have had limited appeal in the past, the new Cummins engine, which produces 500 horsepower and 1,850 pound-feet of torque, is suitable for long-haul applications, making it a potential solution for companies focused on sustainability.

RNG: A Game-Changer for Emissions

Renewable natural gas has the potential to significantly reduce emissions. According to industry estimates, using RNG derived from dairy waste can lead to emissions reductions of up to 300% compared to traditional diesel engines. “When this truck was running in California, it used mostly renewable natural gas, which improves its emissions profile dramatically,” said Otto. However, he cautioned that RNG availability is limited and questioned how much could realistically be produced to support widespread adoption.

Clean Energy Fuels, a leading supplier of RNG, estimates that California’s natural gas consumption is now 98% RNG, with a national adoption rate of close to 80%. This uptake reflects the viability of RNG as a clean fuel source, though its future remains uncertain. Ro admitted that scaling RNG to meet growing demand could be challenging, but emphasized its environmental benefits, as RNG uses methane that would otherwise escape into the atmosphere.

The Road Ahead for Shell’s Starship Program

Shell’s Starship initiative aligns with similar sustainability efforts in the trucking industry, such as the U.S. Department of Energy’s SuperTruck program, which explores various fuel-saving technologies. While SuperTruck concepts often push the boundaries with experimental technologies, Shell’s Starship 3.0 focuses on practical solutions that fleet operators can implement immediately.

Duffy acknowledged that while electrification and hydrogen fuel cells are promising alternatives, they still face significant infrastructure and range challenges. “If we were to switch to hydrogen or electric vehicles, we might be looking at a different version of Starship,” she said, alluding to the ongoing “chicken-or-egg” dilemma regarding infrastructure and vehicle availability. For now, Shell remains focused on maximizing the capabilities of natural gas technology.

Ro believes that Shell’s approach, focusing on natural gas, makes sense in the “messy middle” phase of transitioning to fully renewable solutions. “Battery electric trucks and hydrogen fuel cells might be the future, but they’re not quite ready for long-haul,” he said. He also suggested that natural gas could serve as an interim solution for the next 10 to 20 years, providing a bridge to zero-emission technologies as they continue to evolve.

Natural Gas: A Transitional or Permanent Solution?

Industry experts are divided on whether natural gas will remain a transitional solution or become a permanent fixture in the trucking industry. Ro speculated that natural gas could coexist alongside zero-emission technologies for specific use cases, especially in long-haul trucking where electric vehicles currently fall short.

“I think there’s a real possibility that renewable natural gas becomes part of the ultimate solution,” Ro said, “especially given the double benefit of reducing methane emissions while avoiding petroleum use.” However, he warned that transitioning to a zero-emission future requires careful planning and infrastructure development, making it difficult to predict how natural gas will fit into the broader energy landscape.

Conclusion: A “Lab on Wheels” for a Greener Future

While the future of the Starship program remains uncertain, its contributions to fuel efficiency and emissions reduction are undeniable. Dubbed a “lab on wheels,” Shell’s Starship 3.0 offers a practical glimpse into the future of trucking, providing fleet managers with data and strategies for cutting costs and reducing their carbon footprint.

Whether or not Shell proceeds with a Starship 4.0, the lessons learned from this program are already impacting the industry. As Shell continues to explore sustainable technologies, the Starship project underscores the importance of innovation and collaboration in the race to a greener, more efficient future for trucking.