Innovative Bioreactor Technology for Treating Industrial Residues

U.S. Army Engineer Research and Development Center
Published Jan. 15, 2025
The patent introduces a method that could revolutionize waste treatment processes by effectively neutralizing reducible compounds found in industrial residues.

The patent introduces a method that could revolutionize waste treatment processes by effectively neutralizing reducible compounds found in industrial residues. The patented method uses iron-based materials within the bioreactor to facilitate chemical reactions that break down harmful compounds. The presence of iron creates a conducive environment for microorganisms to thrive, accelerating the degradation of residues and enabling a highly effective treatment process.

The patent introduces a method that could revolutionize waste treatment processes by effectively neutralizing reducible compounds found in industrial residues.

The patent introduces a method that could revolutionize waste treatment processes by effectively neutralizing reducible compounds found in industrial residues. The patented method uses iron-based materials within the bioreactor to facilitate chemical reactions that break down harmful compounds. The presence of iron creates a conducive environment for microorganisms to thrive, accelerating the degradation of residues and enabling a highly effective treatment process.

VICKSBURG, Miss. – The “Method for Treating Reducible Compound Residues Using Iron-Containing Bioreactor” provides a sustainable solution for managing industrial waste by utilizing iron’s unique properties in bioreactors.

Filed in September 2017 and granted in September 2024, the patent was developed by two researchers from the U.S. Army Corps of Engineers.

Dr. Heather Marie Knotek-Smith, research engineer, and David Smith, research ecologist, both with the U.S. Army Engineer Research and Development Center (ERDC), developed this patent that introduces a method that could revolutionize waste treatment processes by effectively neutralizing reducible compounds found in industrial residues.

Addressing the Challenge of Waste Treatment

Industrial processes often produce residues that contain harmful reducible compounds, posing a risk to the environment if not properly managed. Traditional treatment methods can be resource-intensive and may not fully mitigate the impact of these compounds.

This new approach utilizes an iron-containing bioreactor that naturally promotes the reduction of toxic compounds, transforming them into safer byproducts through an eco-friendly process.

How the Iron-Containing Bioreactor Works

The patented method uses iron-based materials within the bioreactor to facilitate chemical reactions that break down harmful compounds. The presence of iron creates a conducive environment for microorganisms to thrive, accelerating the degradation of residues and enabling a highly effective treatment process. This innovation not only reduces the need for external chemical additives but also improves the overall efficiency of the bioreactor.

Research and Development Journey

The path from initial concept to the granting of this patent in September 2024 involved rigorous testing and development by Knotek-Smith and Smith. Initially inspired by natural processes observed in certain wetlands, where iron and microbial interactions break down pollutants, they aimed to replicate and enhance these natural processes within a controlled bioreactor setting. Throughout development, they worked closely with ecologists, chemists and environmental engineers to refine the design, making it scalable and adaptable for diverse applications.

One of the critical challenges was finding the optimal balance between iron levels and microbial activity to maximize degradation without introducing excessive resources. This required extensive lab testing and iterative improvements, ultimately in a robust bioreactor that can withstand industrial-scale operations.

Applications and Benefits

This method can be adapted for a variety of industrial sectors, including chemical manufacturing, mining and wastewater treatment. By implementing this technology, industries can achieve a higher standard of environmental compliance while reducing operational costs associated with residue management. The use of an iron-containing bioreactor offers a significant advantage in sustainability, as it minimizes the environmental footprint of waste treatment processes.

“This approach is easily adaptable to remote locations where daily maintenance or observation isn’t feasible,” said Knotek-Smith. “This makes it ideal for waste streams that are otherwise costly to treat. Further, I believe the approach can be integrated with existing land use and operational practices and is largely passive because the reactor can regenerate its treatment capacity without outside actions.”

For example:

  1. Chemical Manufacturing: Many chemical processes produce a hazardous byproducts. This bioreactor allows on-site treatment of hazardous wastes, reducing reliance on external waste management services and enabling improved compliance with environmental regulations.
  2. Mining: Mining operations often produce toxic residues that are challenging to treat. This bioreactor can help neutralize those residues before they are released into the environment, mitigating the impact of mining on surrounding ecosystems.
  3. Wastewater Treatment: Municipal and industrial wastewater facilities can use the bioreactor to improve treatment efficiency, breaking down pollutants more effectively and reducing the cost and complexity of wastewater management.

The iron-containing bioreactor is a scalable, cost-effective solution for industries of all sizes. By eliminating the need for chemical additives and minimizing operational costs, it offers a sustainable way for industries to achieve higher standards of environmental compliance. This approach supports a shift toward greener, more self-sustaining waste treatment processes.

Environmental and Societal Impact

This patented technology aligns with growing global efforts to minimize industrial waste and support sustainability. By implementing the iron-containing bioreactor, industries can significantly lower their ecological footprint, contributing to cleaner air, soil and water. Additionally, the bioreactor’s minimal resource needs make it a suitable solutions for regions with limited access to advanced waste treatment infrastructure, potentially making a positive global impact.

A Step Forward in Environmental Innovation

This groundbreaking technology exemplifies ERDC’s commitment to advancing environmentally responsible innovations. By providing industries with a scalable and affordable solution for residue treatment, this patented method aligns with growing global sustainability efforts, ensuring a cleaner, safer environment for future generations.