Capital projects involving new processes and technologies don’t always require pilot plant development. However, pilot plants often become indispensable when risk mitigation is critical for large-scale industrial construction. Modular construction offers an innovative solution, allowing pilot plants to be built in controlled environments that address inefficiencies typically associated with on-site construction.
Engineers use pilot plants—small-scale systems—to test and refine new technologies, ensuring they function as intended. These systems enable adjustments to be made when process challenges arise, reducing risks before scaling up to full industrial production.
Pilot plants are characterized by two key factors:
A modular pilot plant is defined by how it is fabricated and constructed. These complex processes occur in a controlled environment, typically in a fabrication shop. A fabrication shop capable of producing modular solutions will contain all equipment, materials, and resources necessary to produce, test, and transport the pilot plant to its final destination.
Modular systems are constructed in steel-incased frames, also known as skids. They can be produced as single units or multiple integrated units designed to perform a specific function or produce a final end product.
Moving construction to a controlled environment enables greater project control, improved safety, and quality levels and reduces some of the variables and inefficiencies that can be introduced by field construction.
Modular pilot plants are designed to enable engineers to test and learn more about specific processes and technologies. Identifying potential problems and optimal configurations and conditions enables engineers to make necessary changes and test those solutions before constructing full-scale industrial plants.
Their design must be flexible enough to enable modifications, enabling modular units to be reconfigured, added, and tested. The following factors will influence design specifications:
Several factors influence the design specifications of modular pilot plants:
Project phases of modular pilot plants are similar to other capital projects. Each phase is required to ensure optimal results:
Modular construction for pilot plant development can provide several attractive benefits in certain applications. However, choosing the modular approach will require a comprehensive evaluation of modular drivers, project requirements, and limitations. We’ve listed the most well-established benefits of modular construction below for consideration.
