Researchers at Colorado State University have developed an intelligent, thermally modulated upflow leach bed reactor (ULBR) system that transforms organic waste into valuable biochemicals such as lactic acid and medium-chain volatile fatty acids (VFAs) with application towards renewable fuels, including sustainable aviation fuel. By precisely controlling temperature, pH, and leachate recirculation, the system maximizes product selectivity while minimizing methane generation and energy use. Automated monitoring and machine learning optimize reactor conditions in real time.
The result is a more efficient, flexible, and sustainable process for converting waste into renewable energy and chemical feedstocks.
Traditional anaerobic digestion systems face inefficiencies when processing high-solids or lignocellulosic wastes, often leading to incomplete breakdown and unwanted methane production. CSU’s innovation integrates real-time sensing, smart thermal control, and adaptive recirculation to overcome these limitations. By directing carbon flow toward specific products rather than gas, this technology bridges waste treatment and chemical manufacturing—offering a step change in waste valorization efficiency.
The CSU system combines multiple upflow leach bed reactors linked by dynamic leachate recirculation and a central control system. Each reactor can operate at tailored temperature and pH “zones”—from mesophilic (35–45 °C) to hyper-thermophilic (65–80 °C)—to guide microbial activity and chemical conversion pathways. Integrated heat pumps recover and redistribute energy between reactors, creating a thermal cascade that reduces heating costs by reusing process heat.
Machine-learning algorithms classify feedstocks, monitor variables such as soluble chemical oxygen demand (sCOD), VFA concentration, and gas composition, and adjust system parameters automatically.
Compared to conventional digesters, this thermally modulated ULBR system increases yield of desired products (e.g., lactic acid, acetic acid, caproic acid) while suppressing methane and excess biomass formation. The modular design enables simultaneous processing of diverse wastes and continuous operation during maintenance or feedstock changes.
Available for Exclusive Licensing, Collaboration or Funding
TRL: 4
US Provisional Patent filed
Luke Loetscher
Sybil Sharvelle
Susan DeLong
Ryan Anderson
Violeta Sanchez Nogue
Steve Foster
Steve.Foster@colostate.edu
970-491-7100