What actually makes up a hydrogen tank system—and how do you refuel safely at 350/700 bar?
In this episode of Hyfindr Tech Talks, Jan Andreas (Argo-Anleg) joins Steven Oji to break down complete hydrogen storage systems for vehicles and vessels. From the on-tank valve (OTV) and thermal pressure relief device (TPRD) to the integrated gas handling unit (GHU) with sensors, solenoid valves, and pressure regulation, Jan explains how systems deliver hydrogen at the right pressure to fuel cells or H₂ ICEs. They also cover refueling protocols, IR communication between vehicle and dispenser, temperature management (pre-cooling to ~–40 °C and tank 65 °C limits), and real-world deployments—from buses and 40-ton trucks to swappable MEGC cartridges on a hydrogen push boat.
You’ll learn about:
System boundaries: refueling interface, tanks with OTV/TPRD, GHU block, outlet to fuel cell/engine
Pressure & regulation: stepping down 350/700 bar to stack/application requirements
Sensing & control: pressure/temperature sensing, solenoids, communications (IR handshake)
Refueling engineering: ramp control, flow rates, hot-spot formation, pre-cooling to manage heat
Applications & sizing: ~5–6 kg (passenger cars), ~20–30 kg (buses/medium trucks), ~40–60 kg (heavy trucks), hundreds of kg for maritime with swappable containers
LH₂ vs compressed H₂: cryogenic challenges (≈–253 °C), boil-off, and why compressed storage often wins on complexity
Ideal for vehicle integrators, storage engineers, and hydrogen infrastructure teams designing safe, efficient H₂ systems end-to-end.
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How do you manufacture fuel-cell bipolar plates with high precision, high yield, and production-scale efficiency?
In this episode of Hyfindr Tech Talks, Fabian Kapp (Gräbener) joins Steven Oji to walk through an end-to-end bipolar plate manufacturing line—from coil to stack-ready plate. Fabian explains hydroforming (up to ~2,500+ bar), precision laser cutting & welding, proprietary straightening for ultra-flat plates, and why cleaning, leak testing, and sealing are critical for quality and cost. He also shares practical lessons on OEE, staffing, and how to reduce scrap by controlling welding and base-material quality.
You’ll learn about:
Process flow: decoiling → hydroforming → cleaning → separation → laser cutting → laser welding → straightening → final clean → leak test → sealing → stacking
Hydroforming details: pressure ranges, flexibility across materials/thicknesses, low tooling cost
Laser operations: edge quality, port accuracy, 3D features, nitrogen assist
Welding quality: fixturing/clamping, stitch seams, leak-tight designs around ports/fields
Flatness & yield: straightening for stackability, scrap reduction, optical inspection
Production reality: leak testing (pressure-drop/helium), staffing, maintenance windows, and OEE best practices
Ideal for manufacturing engineers, operations leaders, and stack designers scaling fuel-cell production lines.
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How do hydrogen pressure relief valves ensure safety across fuel cell and storage systems?
In this episode of Hyfindr Tech Talks, Olaf Schulenberg (Goetze KG) joins Steven Oji to explain the engineering behind spring-loaded hydrogen pressure relief valves — a critical component for ensuring safety in electrolyzers, storage tanks, and liquid hydrogen systems.
Olaf breaks down how these valves regulate excess pressure, their internal mechanics, and the importance of certification, testing, and temperature resilience in hydrogen applications. The discussion highlights how robust valve design and monitoring systems prevent failures and maintain safe operating conditions across diverse hydrogen environments.
You’ll learn about:
How spring-loaded pressure relief valves function in hydrogen systems
Safety principles and design features ensuring pressure control
Testing & certification requirements for cryogenic and high-pressure use
Applications in electrolyzers, storage systems, and LH₂ transport
Maintenance and monitoring best practices for long-term reliability
Perfect for engineers, safety experts, and hydrogen professionals focused on system integrity, certification, and pressure management in the hydrogen economy.
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What’s the real carbon intensity of hydrogen—once you include production and delivery?
In this episode of Hyfindr Tech Talks, Greg Powers (Chief Innovation Officer, BayoTech) joins Steven Oji to break down hydrogen production pathways and how to measure their carbon intensity (CI) across the full lifecycle. From steam methane reforming (SMR) vs electrolysis, to distributed SMR with high heat-recovery reactors, to using renewable natural gas (RNG) for carbon-negative outcomes, Greg explains the engineering trade-offs behind cost, efficiency, and emissions.
You’ll learn about:
Hydrogen pathways: SMR, electrolysis, coal gasification (context), and nuclear heat/electricity coupling
Gross vs. net impacts: why compression, liquefaction, transport, and storage change CI
Distributed SMR design: bayonet reactors, heat integration, and water/energy efficiency
CI metrics: energy-based (gCO₂e/MJ) vs mass-based (kg CO₂/kg H₂) and how to translate between them
Grid vs renewables: why CI varies by electricity mix; when electrolysis shines
RNG credits & carbon math: capturing methane from waste streams and pathways to zero or negative CI
Perfect for engineers, developers, and decision-makers who want a clear, technical view of hydrogen production and lifecycle emissions—without the politics.
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How do pressure regulators deliver stable hydrogen pressure and flow for fuel cells, refueling, and electrolysis—safely and efficiently?
In this episode of Hyfindr Tech Talks, Jack Samways (Pressure Tech) joins Steven Oji from the factory floor to unpack pressure regulator fundamentals and real-world hydrogen applications. Jack explains spring-loaded (manual) vs air-loaded (PLC-controlled) regulators, the decaying inlet effect, balanced main valves, and two-stage designs used for high-pressure systems. You’ll also hear where regulators fit across the hydrogen ecosystem—from electrolyzers and refueling stations to trucks, buses, and fuel cell stacks.
You’ll learn about:
Regulator basics: reducing 350–700 bar down to precise set pressures for fuel cells
Flow vs. pressure requirements: orifice/Cv sizing for accurate delivery
Stability & accuracy: decaying inlet effect, balanced main valve, and two-stage approaches
Control strategies: manual set-and-forget vs air-loaded regulators with PLC control (ramp rates, temperature/pressure corridors)
Where they’re used: electrolyzers (back-pressure regulation), H₂ refueling, and vehicle fuel cell systems
Safety & standards (overview): responsiveness to J2601 fueling profiles, robust design practices aligned with hydrogen high-pressure expectations
Perfect for system engineers, safety leads, and fuel cell integrators who need reliable pressure control across hydrogen applications.
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How do you tune a hydrogen fuel cell system for maximum efficiency, lifetime, and performance?
In this episode of Hyfindr Tech Talks, Christoph Ley (AE Driven) returns to join Steven Oji for a deep dive into fuel cell system optimization—from stack operating points to Balance of Plant (BoP) choices. They unpack gross vs. net efficiency, the real cost of compressor power, cooling requirements, and how hybrid strategies (fuel cell + battery) handle peaks without sacrificing efficiency or lifetime.
You’ll learn about:
BoP fundamentals: anode/cathode/cooling loops and what to optimize first
Gross vs. net efficiency: why compressor and auxiliary loads change the picture
Pressure & airflow trade-offs: more power vs. efficiency, degradation, and hydrogen use
Hybridization: sizing fuel cell and battery to meet load profiles and peak demands
Lifetime & TCO: running at part-load, multi-stack strategies, and durability impacts
Component selection: compressors, DC-DC, and cooling sized for the true operating zone
Perfect for system engineers, integrators, and product owners aiming to hit performance targets while protecting lifetime and total cost of ownership.
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What goes into designing a complete PEM fuel cell system?
In this episode of Hyfindr Tech Talks, Christoph Ley (AE Driven) joins Steven Oji (Hyfindr) to break down the essential components and processes that make up the Balance of Plant (BoP) in a PEM fuel cell system. They explain how everything—from managing high-pressure hydrogen to cooling and air supply—is integrated to make the fuel cell stack function efficiently.
You’ll learn about:
The core function and components of a PEM fuel cell.
What the Balance of Plant (BoP) includes (anode, cathode, cooling, and power electronics).
How high-pressure hydrogen is regulated for the anode system.
The role of the cathode system in providing oxygen and membrane hydration.
The challenges and timeline involved in selecting the right components for a system design.
This episode is perfect for engineers, researchers, and hydrogen professionals interested in the architecture, integration, and development of functional fuel cell systems.
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What’s the future of DC-DC converters in the hydrogen industry?
In this episode of Hyfindr Tech Talks, Thomas Vetter (Aradex) joins Steven Oji (Hyfindr) to discuss the use, design, and future of DC-DC converters in fuel cell systems. They explain why these converters are essential to adapt the fuel cell's direct current voltage to a vehicle's high-voltage system, and the crucial role they play in the transition to higher system voltages (e.g., in trucks) which allows for smaller, lighter, and cheaper cables.
You’ll learn about:
Why step-up DC-DC converters are needed for fuel cell technology.
The working principles and components of fuel cell DC-DC converters.
Challenges related to increasing the step-up ratio to meet higher target voltages.
The impact of switching frequency on converter size and efficiency.
Future developments in DC-DC converters, including the role of FPGA and Electro Impedance Spectroscopy (EIS).
This episode is perfect for engineers, researchers, and hydrogen professionals interested in power electronics, fuel cell system design, and the push towards higher voltage hydrogen applications.
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What role do cathode air blowers play in stationary hydrogen fuel cells?
In this episode of Hyfindr Tech Talks, Marc Franzbäcker (Gebr. Becker GmbH) joins Steven Oji (Hyfindr) to explain the design and operation of cathode blowers for stationary fuel cell systems. From side channel technology to efficiency improvements, Marc highlights how modern blowers balance airflow, pressure, and energy consumption in hydrogen applications.
You’ll learn about:
The difference between blowers and compressors in fuel cell systems
Types of blowers: claw compressors, turbo blowers, and side channel blowers
How cathode blowers ensure efficient airflow while minimizing parasitic load
Design features such as permanent magnet motors, silencers, and oil-free operation
Applications of cathode blowers in stationary hydrogen fuel cell systems
This episode is perfect for engineers, researchers, and hydrogen professionals interested in fuel cell air management and system efficiency.
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Why are filters so critical in hydrogen fuel cell systems?
In this episode of Hyfindr Tech Talks, Dominik Bauer (Solberg International) joins Steven Oji (Hyfindr) to explain the role of fuel cell air intake and cathode filters in protecting both equipment and the environment. From particle and oil mist removal to activated carbon filtration, Dominik shows how advanced filter design ensures clean air supply, protects catalysts, and extends the life of hydrogen fuel cells.
You’ll learn about:
How fuel cell filters protect systems from particles, liquids, and harmful gases
The importance of cathode filtration in hydrogen fuel cell stacks
Materials used in fuel cell filters (polyester layers, activated carbon, etc.)
How contaminants like SO₂, NO₂, and ammonia can damage membranes and catalysts
Engineering considerations: filter surface area, efficiency, and adsorption capacity
This episode is ideal for engineers, researchers, and hydrogen professionals working on fuel cell system design, reliability, and performance.
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Can hydrogen-powered portable chargers make EV charging more flexible and accessible?
In this episode of Hyfindr Tech Talks, Jiří Vršínský (DEVINN) joins Steven Oji (Hyfindr) to discuss semi-autonomous hydrogen-powered mobile charging solutions for electric and hybrid vehicles. From the H2BASE generator to the H2BOT mobile charger, Jiří explains how hydrogen fuel cells, batteries, and smart power management systems work together to deliver charging where grid access is limited.
You’ll learn about:
Why mobile EV charging is needed for blind spots and remote areas
How hydrogen fuel cells integrate with batteries and DC-DC converters
Components of a hydrogen-powered charger: fuel cell, hydrogen storage, power electronics, and communication units
The role of power management in balancing vehicle SOC, battery SOC, and fuel cell output
Future innovations like robotic arms for automated EV connection
This episode is perfect for engineers, researchers, and professionals exploring hydrogen mobility, EV infrastructure, and next-generation charging solutions.
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How does cascade management ensure safe and efficient hydrogen refueling?
In this episode of Hyfindr Tech Talks, Rico Schöni (Eugen Seitz) joins Steven Oji (Hyfindr) to explain the pressure regulation systems that power modern hydrogen refueling stations. From mosaic valve technology to flow panels with 40 integrated valves, Rico shows how smart valve and sensor systems enable smooth pressure control, reduce failure points, and improve reliability in hydrogen mobility.
You’ll learn about:
This episode is ideal for engineers, hydrogen station developers, and professionals building the infrastructure for hydrogen mobility.
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How do you measure hydrogen purity and detect impurities like moisture and oxygen?
In this episode of Hyfindr Tech Talks, Aleksandar Trajanovski (Panametrics, a Baker Hughes business) joins Steven Oji (Hyfindr) to explain the role of binary gas analyzers, moisture transmitters, and oxygen analyzers in hydrogen production. From ensuring PEM electrolyzer safety to meeting purity grades for industrial use, Aleksandar breaks down how these instruments protect processes and improve product quality.
You’ll learn about:
The role of binary gas analyzers in preventing gas crossover during electrolysis
Moisture transmitters and their importance in hydrogen drying systems
Oxygen analyzers for monitoring concentration in hydrogen output
Thermal conductivity measurement principles in hydrogen analyzers
How stable and reliable sensors ensure continuous operation in hydrogen plants
This deep dive is essential for engineers, researchers, and professionals focused on hydrogen production and process safety.
Discover more at Hyfindr.com and join the Hyfindr Tech Community to connect with experts shaping hydrogen technology worldwide.
What makes a hydrogen fuel cell stack efficient, durable, and ready for real-world applications?
In this episode of Hyfindr Tech Talks, Roger Penn (AVL Fuel Cell Canada) joins Steven Oji (Hyfindr) to explain the engineering considerations behind fuel cell stack design. From voltage matching and thermal management to packaging, vibration resistance, and application-specific requirements, Roger shares insights from decades of experience in hydrogen fuel cell development.
You’ll learn about:
How the number of cells and active area define stack power and efficiency
The role of DC-DC converters in fuel cell stack integration
Polarization curves (voltage vs. current density) in design decisions
Managing heat rejection, compression force, and material stress
Shock and vibration resistance in automotive, marine, and rail applications
This episode is perfect for engineers, researchers, and innovators working on hydrogen fuel cell systems who want to understand what it takes to design robust, high-performance stacks.
Explore more at Hyfindr.com and connect with professionals advancing the hydrogen economy.
How can hydrogen leaks and invisible flames be detected safely and reliably?
In this episode of Hyfindr Tech Talks, Claudio Fecarotta (MSA Safety) joins Steven Oji (Hyfindr) to explain the latest hydrogen sensor technologies. From ultrasonic leak detection and catalytic sensors to advanced flame detectors, Claudio shows how multiple layers of sensing technology protect hydrogen refueling stations, vehicles, and infrastructure.
You’ll learn about:
Ultrasonic Gas Leak Detectors (UGLD) and their coverage in hydrogen stations
Conventional catalytic and electrochemical hydrogen gas sensors (up to 1000 ppm)
Hydrogen flame detectors using UV/IR technology for invisible flames
How AI (artificial neural networks) reduce false alarms in leak detection
Safety regulations (ISO 19880) and required instrumentation for hydrogen sites
Engineers, safety specialists, and hydrogen innovators will gain insights into how these detectors form a comprehensive protection system for the growing hydrogen economy.
Discover more at Hyfindr.com and join us while shaping hydrogen technology worldwide.
Bipolar plates are at the heart of hydrogen fuel cells and electrolysers but how are they formed, and why are they so critical to efficiency?
In this episode of Hyfindr Tech Talks, Simon Brugger (CellForm) joins Steven Oji to explain the science and engineering behind fuel cell bipolar plates. From stainless steel forming and PVD coatings to precision laser welding, Simon reveals how bipolar plates are designed, manufactured, and tested for maximum accuracy and performance.
You’ll learn about:
The role of bipolar plates in fuel cell and electrolyser stacks
How plate forming and welding affect fuel cell efficiency
Material choices: stainless steel, titanium, coatings, and conductivity
Quality assurance, leak testing, and micro-accuracy (≤10 microns)
The cost challenge: making bipolar plates scalable for hydrogen mobility
For engineers, researchers, and innovators in hydrogen technology, this is a deep dive into one of the most crucial components of fuel cell systems.
Discover more at Hyfindr.com and join us while shaping hydrogen technology worldwide.
How do inverters power hydrogen fuel cell and battery electric vehicles?
In this episode of Hyfindr Tech Talks, Jon Duroudier (ePowerlabs) joins Steven Oji (Hyfindr) to explain how fuel cell inverters and motor controllers enable efficient, reliable powertrains for hydrogen and electric mobility. From conversion of DC to AC power, to torque control, cooling, and cloud connectivity, Jon breaks down the engineering behind traction inverters.
You’ll learn about:
The role of traction inverters in hydrogen and battery EVs (FCEV & BEV)
How inverters convert DC from fuel cells or batteries into AC for motors
Interaction of inverters with compressors, fans, and auxiliary components
Testing, diagnostics, and remote monitoring for inverter performance
Why inverter design is critical for efficiency, safety, and scalability in e-mobility
Ideal for engineers, researchers, and innovators in hydrogen and electric powertrain technology.
Discover more at Hyfindr.com and join us while shaping hydrogen technology worldwide.
Solid oxide fuel cells (SOFC) and solid oxide electrolysis cells (SOEC) rely on advanced plate heat exchangers to manage extreme temperatures of up to 700 °C. In this episode of Hyfindr Tech Talks, Stephan Pflugfelder (smk – systeme metall kunststoff) joins Steven Oji to explain how heat exchangers enable efficiency, reliability, and safety in hydrogen fuel cell systems.
You’ll discover:
The difference between SOFC and SOEC technology
How hydrogen heat exchangers stabilize fuel cell stacks
Engineering challenges such as pressure drop, gas flow, and thermomechanical stress
Why SOFC systems are ideal for continuous 24/7 operation
The future of hydrogen heat exchanger design
Ideal for engineers, researchers, and innovators in the hydrogen economy. Learn more at Hyfindr.com and join the Hyfindr Tech Community to connect with professionals shaping hydrogen technology worldwide.
Hydrogen refueling stations are a cornerstone of the hydrogen economy — but how do sensors, gauges, and measurement technology make them safe and reliable?
In this episode of Hyfindr Tech Talks, Christian Wirl (WIKA) joins Steven Oji (Hyfindr) to explain the engineering behind hydrogen refueling station instrumentation. From pressure gauges with Swiss Movement technology to explosion-proof transmitters and thermal sensors, Christian demonstrates the devices that keep hydrogen cars, buses, and trucks fueled safely.
You’ll learn about:
Instrumentation design in hydrogen refueling stations (HRS)
Pressure gauges, transmitters, and thermal sensors in action
The role of 316L steel in preventing hydrogen embrittlement
Managing hydrogen temperature during fueling (-40 °C to +85 °C)
Engineering standards and safety challenges in HRS technology
Engineers, researchers, and innovators in hydrogen mobility will gain valuable insight into one of the most critical enabling technologies of the hydrogen economy.
Discover more at Hyfindr.com and join us while shaping hydrogen technology worldwide.