Design files and data for a lab-scale methane biofiltration system

Methane (CH4) is a potent greenhouse gas with a global warming potential 27–30 times greater than CO2. Diffuse sources such as livestock facilities, landfills, and coal mines emit methane at low concentrations (<5% v/v), limiting the applicability of conventional mitigation technologies. Biofiltration, which uses methanotrophic bacteria to oxidize CH4 to CO2, offers a sustainable alternative but lacks standardized hardware, resulting in inconsistent designs and limited reproducibility. We present an open-source, modular lab-scale biofiltration system optimized for continuous operation and experimental replication. The system comprises triplicate packed-bed columns constructed from chemically resistant materials, integrated with mass flow controllers for precise gas delivery, humidifiers to maintain moisture, and standardized fittings for leak-free assembly. Its transparent columns enable visual monitoring, and the bottom-up flow design minimizes media compaction. Validation at an inlet concentration of 0.5% CH4 achieved mean removal efficiencies of 89.0 ± 6.7%. Design files, bill of materials, and assembly instructions are provided under a CERN OHL license to facilitate adoption and customization. This hardware supports methane mitigation research and broader applications in gas-phase bioprocessing, enabling reproducible studies and accelerating development of scalable biofiltration technologies.

This repository includes the design files for the hardware, the bill of materials, and the data obtained during hardware validation for three biofilters ran as replicates. The design files include all CAD files and 3D printing files for the biofilter head/baseplates, as well as frame feet, extrusion mount, and tube clamps to mount the biofilter in its support. Additionally, the files include a metal grate added inside the biofilter for solid media support and a manometer mount.
Headplate/Baseplate: The headplate and baseplate provide the seal for the top and bottom of the biofilter and humidifier columns. Design files, including CAD and shop drawings, are provided for machining.
Frame Feet: These 3D-printed parts press-fit into the 2020 aluminum frame. Both STL and 3MF files are provided, and the latter include print settings.
Extrusion Mount: The biofilter sits on this 3D-printed part, which bolts to the 2020 aluminum frame. Both STL and 3MF files are provided, and the latter include print settings.
Biofilter Tube Clamp: These two parts, which are mirror images of one another, clamp the outside of the biofilter column to provide a mounting point. CAD and STL files are provided for both the left and right tube clamp. 3MF files include both sides printed together with appropriate print settings.
Metal Grate: These discs are laser cut from stainless steel and support the solid medium inside the biofilter column. DXF files are provided for laser-cutting services.