Evolution of Hydrogen Transport and High Pressure Valves

At the forefront of hydrogen transport technology, BayoTech continues to push the boundaries of high-pressure solutions with its innovative products. In this interview, Greg Powers, Chief Innovation Officer, discusses the evolution of BayoTech’s HyFill® trailers and the company's latest breakthrough, the NorAm EVOtech™ valve.

Q: Greg, BayoTech’s HyFill trailers have made a significant impact in the hydrogen transport industry. Could you give us an overview of what sets these trailers apart?

Absolutely. Our HyFill trailers use high-pressure Type III cylinder technology, allowing us to store and transport more compressed gas in a smaller footprint than traditional steel cylinders. This means higher payloads per trailer, enabling customers to refuel more sites with fewer trips. The result is lower transportation costs, increased driver productivity, and reduced emissions.

Our Tridem model, for example, carries 750 kilograms of hydrogen in cylinders on a 40’ trailer. We utilize a cascade filling system to maximize gas delivery via equalization filling. Each trailer features a pneumatic control system, allowing operators to safely offload hydrogen from ground level. This setup enhances safety, avoids electronics issues related to Class I Div 2 compliance, and improves overall efficiency.

Q: One of the core components of the HyFill trailer is the proprietary valve design. What role do these valves play in enhancing performance?

Our proprietary NorAm valves are essential to the performance of the HyFill trailers. They control the movement of compressed gas, allowing for efficient filling of the cylinders for transport and emptying of the cylinders at delivery. The valves are built with long-lasting seals to prevent hydrogen leakage, which is critical in high-pressure applications like hydrogen transport.

Each valve includes an integral Thermal Pressure Relief Device (TPRD), which safely vents hydrogen in case of fire. And our pneumatic control system allows the operators to open and close the valves without climbing onto the trailer itself. This eliminates the need for operators to climb onto the trailer. It’s a proven reliable system and allows for safer operation by personnel.

Q: BayoTech recently announced the launch of the NorAm EVOtech valve. What are the key benefits of this new design?

We’re very excited about the NorAm EVOtech valve—it represents the next evolution in our valve technology. There are several key benefits:

• Uptime and Utilization: The NorAm EVOtech features greater leak resistance, meaning trailers spend less time undergoing maintenance or valve replacements.
• Safety: Enhanced leak protection is crucial, especially with hydrogen, where safety is always a priority. This valve is bi-directional – meaning both leak tight in the filling direction and dispensing direction. When our valves are closed, no pressure buildup accrues in the manifolds.
• Durability: The new valve design is built for reliability, with longer-lasting seals and a greater lifecycle expectancy.
• Rebuildability: One of the standout features is that the internals can be rebuilt, saving customers both time and money.
• Reverse Compatibility: We’ve also made sure that the new design is reverse compatible. Legacy valves can be rebuilt to meet the new standards using our rebuild kits.

Q: It’s clear that safety and reliability are at the core of BayoTech’s product philosophy. Can you speak more about the rigorous testing processes these valves undergo?

Safety is non-negotiable for us. Every single valve we ship is leak tested—100% of them. Each valve is tested for leak tightness at 1.25 x mawp, which is over 9,000 psi. We conduct two-way leak verification at both high and low pressure to ensure the integrity of the valve under different conditions. Our processes meet or exceed the most stringent industry standards, including those set by the U.S. Department of Transportation (DOT) and the Compressed Gas Association (CGA). This rigorous approach is one reason we’ve shipped over 25,000 valves with a proven track record of safe and long-lasting use in high-pressure applications.

We also conduct extensive lifecycle testing, simulating up to 15 years of operation, which is the maximum service life of a Type III cylinder. This ensures that our valves deliver consistent performance over the long term.

Q: BayoTech has clearly invested a lot into refining your valve designs. How does this fit into your larger vision for hydrogen transport?

As hydrogen applications continue to grow, particularly for commercial use, the demand for safe, efficient, and reliable high-pressure transport solutions will only increase. At BayoTech, we take ownership of the entire trailer integration from end to end. This gives us control over optimizing performance at every level. We also focus on user experience and look to make the ergonomics of filling and dispensing easier with every generation. Our continuous investment in valve technology is just one part of our broader commitment to meeting the evolving needs of the market.

With the NorAm EVOtech valve, we’re preparing for the future—higher pressures, more complex applications, and greater demand for hydrogen. Our focus remains on increasing payload efficiency while maintaining top-tier safety and reliability.

Q: For customers currently using legacy valves, is there a pathway to upgrade to the NorAm EVOtech?

Definitely. We’re offering programs to upgrade all legacy valves to the new design. The valves are reverse compatible and can be upgraded via a rebuild kit. This enables us to seamlessly upgrade customers to the new design while saving them cost and time. Our skilled technicians are certified to provide repairs either in the field or at our BayoTech facilities, and if a new valve is needed, we carry a buffer stock to ensure replacements can be expedited. We’re also extending the warranty on all valves certified to the new design, giving customers added peace of mind.

Q: What’s next for high-pressure hydrogen equipment?

We’re continually evolving. With over 800 units in the field, we have the experience and insights needed to push the industry forward. The launch of the NorAm EVOtech valve is just one step in our journey. We remain focused on innovation, ensuring that our products meet the demands of an increasingly hydrogen-powered world.

We have a roadmap centered on customer satisfaction. Our customers depend on us for more than just cutting-edge technology—they count on our long-term commitment to reliability, safety, and performance. We're focused on increasing the hydrogen carrying capacity of each trailer to deliver greater value. Ease and flexibility in filling and dispensing are key considerations in our designs. We're proud of our progress, and there’s much more to come as we continue to push the boundaries of hydrogen transport technology.

Q: Thanks for your insights, Greg. It’s exciting to see BayoTech leading the charge in hydrogen transport innovation.

Thank you—it’s an exciting time for the industry, and we’re thrilled to be at the forefront of these advancements.

Conclusion 

Stay tuned to the BayoTech blog for more updates on our innovations and industry insights. For more information on the NorAm EVOtech valve and our HyFill trailers, visit our website or contact us directly at info@bayotech.us.