Advertise on podcast: Hyfindr Tech Talks Hydrogen | Fuel Cell | Technology

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. Explore more at Hyfindr.com

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. Explore more at Hyfindr.com

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. Explore more at ⁠Hyfindr.com

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. Explore more at ⁠Hyfindr.com

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. Explore more at Hyfindr.com

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. Explore more at Hyfindr.com

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. Discover more at Hyfindr.com

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. Discover more at Hyfindr.com

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. Discover more at Hyfindr.com

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. Discover more at Hyfindr.com

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. Discover more at Hyfindr.com

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: The principles of cascade filling in hydrogen refueling stationsHow solenoid valves and flow panels regulate hydrogen pressureThe role of sensors in creating safe, smooth fueling curvesEngineering challenges in reducing failure points at scaleWhy cascade management is key for buses, trucks, and hydrogen carsThis episode is ideal for engineers, hydrogen station developers, and professionals building the infrastructure for hydrogen mobility. Discover more at Hyfindr.com

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.