Pilot & Bench Scale Testing
Laboratory Services

Pilot & Bench Scale Testing for Industrial Water Projects

Validate treatment performance before scale and capital are committed

Chemical Modelling, Microbiology, and Genomics Laboratory Services

Our approach to informed water treatment design

Test operating ranges, process sensitivities, and scale-up requirements under representative conditions

Testing programs begin by defining the technical question, required level of evidence, and decision thresholds that determine whether a process advances, changes, or requires further validation. The testing program establishes representative water conditions, operating variables, controls, sampling frequencies, stabilization periods, analytical methods, and QA/QC requirements appropriate to the technology and development stage.

Interpretation considers more than peak removal performance. Data are evaluated for repeatability, sensitivity, operating stability, reagent demand, residuals behaviour, response time, failure modes, and the limitations created by test duration or scale. These findings are then carried into model calibration, technology comparison, preliminary design criteria, vendor requirements, scale-up allowances, permitting evidence, and future commissioning plans.

Chemical Modelling, Microbiology, and Genomics Laboratory Services
service outcomes

reduce process performance uncertainty

Pilot and bench testing convert assumed performance into observed evidence that can be used to validate feasibility, scale risk, and regulatory confidence before project decisions lock-in.

Chemical Modelling, Microbiology, and Genomics Laboratory Services
sustained performance

Preserving evidence value over time

Pilot and bench-scale testing provide an initial evidence base, not a one-time answer. Performance over time is achieved by carrying test insights forward into ramp-up, monitoring, and operational decision-making.

Mobile laboratory outputs define analytical methods, calibration, conditions, and observed context on-site in near real-time, so results remain quickly accessible and interpretable during operations. Combined with our baseline analysis, our outputs support project continuity by allowing future teams to compare, revisit, or supplement field evidence without treating short-term observations as fixed conclusions or losing their situational relevance as projects progress.

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explore our latest projects

gbbr performance assessment and technology readiness evaluation
Mining Water Infrastructure Development and Equipment
In Situ Ammonia Treatment Feasibility Evaluation and Barrel Trails
Mine Constructed Wetland Treatment System Pilot Testing and Expert Panel Review
Mine Water Treatment Plant Permit Application Amendment Engineering Support
Pit Lake Treatment Bench Trials and Technology Readiness Assessment
Equipment-Landscape-14
Thermal Heavy Oil Facility Water Process Optimization

Nitrate and Selenium Treatment Performance Review for Gravel Bed Bioreactor (GBBR) Retrofit

Integrated Sustainability assessed conversion of existing biochemical reactor basins to gravel bed bioreactors for nitrate and selenium treatment, including performance modelling and technology readiness evaluation.

Canada’s 1st Commercial-Scale moving bed bioreactor (MBBR) Treating Selenium and Nitrate at 520 gpm

Integrated Sustainability delivered Canada’s first commercial-scale moving bed biofilm reactor (MBBR) system for selenium and nitrate removal from mine effluent. Full-service design, equipment supply, and field engineering supported a 520 gpm facility.

Laboratory Trials Validating In Situ Ammonia Assimilation in Tailings Pond

Integrated Sustainability evaluated in situ ammonia treatment for mine tailings through feasibility assessment and barrel-scale testing, refining dosing, treatment timeframes, and geochemical effects for scale-up.

Design, Construction and Operation of Passive Water Treatment System

Integrated Sustainability designed and operated a year-long constructed wetland treatment pilot, validating performance under updated site conditions and supporting regulatory review ahead of demonstration-scale deployment.

High Density Sludge and Biological Treatment Design for Metals and Nitrogen Control Permitting

Integrated Sustainability completed conceptual design of a mine water treatment plant for a Joint Permit Amendment Application, integrating metals removal, biological nitrogen treatment, and existing nanofiltration.

Biogeochemical Treatment Trials for Molybdenum and Uranium in Pit Lakes

Integrated Sustainability evaluated in situ biogeochemical treatment for molybdenum and uranium in pit lakes, advancing technology readiness through bench-scale trials and generating design inputs for field-scale implementation.

20+ Modular H2S Scavenger Packages Design and Delivered to US & Canadian Clients

Integrated Sustainability has designed/built over 20 H2S scavenging skids, including 2 of the largest H2S scavenging skid packages in Alberta with each skid having the capacity to treat up to 10,000 ppm of total sulfur content.

Water Treatment Optimization for Steam Generation at a Thermal Heavy Oil Facility

Integrated Sustainability optimized water treatment for a thermal heavy oil steam generation facility, providing ongoing technical support for startup, water quality, and system performance.
Chemical Modelling, Microbiology, and Genomics Laboratory Services

What is the difference between bench-scale and pilot-scale testing?

Bench-scale testing uses smaller, controlled systems to screen treatment pathways, reagents, media, operating ranges, and key sensitivities efficiently. Pilot-scale testing evaluates a more integrated process under continuous or field-representative conditions, providing greater insight into hydraulics, process controls, fouling, residuals management, operational stability, and scale-up requirements.

How long must a test operate before results are considered reliable?

The required duration depends on the process, residence time, startup or biological acclimation requirements, and the variability being evaluated. Reliability should be based on predefined stabilization and data-quality criteria, sufficient operating cycles, reproducible performance, and adequate representation of expected variability rather than on an arbitrary number of days.

How do you ensure that test water and operating conditions are representative?

Testing conditions are selected using site-water characterization, anticipated operating ranges, seasonal variability, and credible worst-case or upset scenarios. Actual site water is used where practical, with sample collection, storage, aging, and preparation documented. If site water is not accessible, then we prepare synthetic water in our laboratory to reproduce site-specific water quality. Key parameters such as temperature, pH, redox conditions, suspended solids, constituent concentrations, hydraulic loading, and reagent dosing are controlled or monitored throughout testing.

When is pilot or bench testing most appropriate?

Bench testing is useful for screening treatment chemistry, reagents, media, and controlling variables. Pilot testing is appropriate when continuous operation, hydraulic behaviour, process controls, residuals, fouling, seasonal variability, or scale-dependent performance must be evaluated before design, investment, or permitting decisions are finalized.

Does this guarantee full-scale performance?

No. Testing reduces and defines scale-up uncertainty but cannot eliminate it. Full-scale performance can also be affected by hydraulics, mixing and mass transfer, residence-time distribution, heat loss, fouling and scaling, biomass acclimation, instrumentation and controls, feed variability, and test duration.

How are test conditions selected?

Conditions are selected from the decision objectives, representative water characterization, anticipated operating envelope, and credible seasonal or upset scenarios. Programs typically include baseline conditions, controls, suitable replication, performance limits, stabilization criteria, and clearly documented assumptions.

Can testing support regulatory submissions?

Yes. Empirical data can support regulatory submissions when the program is fit for the regulatory question and includes documented methods, QA/QC, representative conditions, and interpretation limits. Early alignment with the regulator may be advisable where the test will form a material part of the permitting basis.

Is this suitable for operating assets?

Yes. Bench and pilot testing can support troubleshooting, reagent optimization, process changes, debottlenecking, alternate feed conditions, residuals management, and technology upgrades. Testing complements rather than replaces routine operational monitoring.

Lifecycle Accountability for Industrial Water Assets

Combine deep technical expertise with execution and operational experience

Complex and high-consequence industrial projects require a practical mindset to enable agile development and positive environmental outcomes.

Our vertically integrated water services platform combines science, engineering, equipment fabrication, and operations to provide fit-for-purpose assets that drive accountability and performance.

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Test early treatment assumptions

Engage with our specialists to determine whether pilot or bench testing could clarify feasibility, regulatory confidence, or scale-up risk.