Thermal Management in Metal Hydride Hydrogen Storage Reactors: Mechanisms, Architectures, and Design Trade-Offs

Metal hydride-based hydrogen storage reactors combine high volumetric hydrogen density with intrinsic safety, yet their performance is fundamentally limited by inefficient thermal management arising from the strong coupling among heat transfer, thermodynamics, and reaction kinetics. The highly exothermic and endothermic nature of hydrogen absorption and desorption requires rapid and spatially uniform heat removal or supply, which is difficult to achieve due to the low thermal conductivity and complex internal structure of hydride beds. This review presents a mechanistic and architectural overview of thermal management in metal hydride hydrogen storage reactors. Key heat transfer limitations within hydride beds are first analyzed, followed by a systematic classification and critical comparison of major thermal management architectures, including bed-level modifications, structural reactor designs, and heat-exchanger intensification strategies such as embedded tubes, fins, and phase-change materials. The advantages and limitations of these approaches are discussed in terms of heat transfer efficiency, hydrogen storage capacity, structural complexity, and scalability. Finally, the review highlights the central design trade-offs governing compactness, efficiency, and manufacturability, and outlines future directions toward application-oriented and scalable reactor design through integrated thermal and structural optimization.