Treatability Studies Guide
Comprehensive guide to wastewater treatability testing, jar testing, and process selection methodology
Comprehensive pilot testing services, custom pilot plant design, and treatability studies that validate process performance and generate design data for full-scale water treatment systems
Preventive and reactive maintenance for critical water treatment processes plants.
CFD, P&ID, SCADA and commissioning for critical water treatment plants.
Professional P&ID development and engineering documentation. Process flow diagrams, instrumentation, control loops and HAZOP.
Chemical industry wastewater treatment for chemical conditioning and treatment.
Pilot testing is the critical bridge between theoretical process design and operational reality. At Reynolds & Bauhm we design and execute pilot programmes that generate defensible, full-scale engineering data under conditions that faithfully replicate your intended operating envelope. Whether you need a containerised unit deployed to site within a fortnight or an extended multi-train study at our controlled facility, our chartered engineers ensure every test is instrumented, sampled and analysed to the standard required for regulatory submission and capital-investment approval.
Our approach integrates process engineering, analytical chemistry and mechanical design into a single accountable workflow — so the data you receive is not merely observed, but interpreted into actionable design specifications, operating parameters and cost models.
Behind the design sits a full modelling toolkit — CFD, process simulation, biokinetic (ASM/ADM), reaction-kinetics, hydraulic, limnological and data-driven digital-twin modelling. We pick, or combine, the disciplines that answer your question and validate them against real data.
Explore Scientific ModellingFrom process design and equipment supply through installation, commissioning and handover, we deliver complete treatment plants as a single-responsibility turnkey package — one contract, one accountable partner, and a defined performance guarantee.
Explore Turnkey DeliveryFrom Custom Pilot Plants to Scale-Up Validation
Custom-designed pilot plants tailored to your specific process requirements. We handle everything from conceptual design through fabrication, installation, and commissioning.
Comprehensive treatability studies to determine the most effective treatment approach for your specific wastewater characteristics and discharge requirements.
Detailed analysis of process performance including chemical, physical, and biological parameters to ensure your process meets all treatment objectives.
Expert guidance on scaling from pilot to full-scale operations, including process optimisation to maximise efficiency and minimise operating costs.
Validate equipment performance under real-world conditions to ensure selected technologies will meet design specifications and operational requirements.
Detailed technical reports with data analysis, recommendations, and specifications for full-scale system design and procurement.
Every successful pilot programme begins with a plant that accurately reproduces the hydraulics, kinetics and mass-transfer characteristics of the full-scale process. We do not repurpose off-the-shelf skids to approximate your requirements; we design and fabricate bespoke pilot plants configured to your specific wastewater matrix, flow regime and treatment objectives.
From reactor geometry and mixer specification to instrumentation selection and control philosophy, our designs are governed by a formal Basis of Design developed with your team. We manage fabrication through qualified workshops, supervise installation and commission each unit with full operational handover and operator training. Mobile configurations are engineered for rapid deployment with minimal civil preparation, while fixed facilities support long-duration studies with continuous remote monitoring and full laboratory back-up.
Selecting the wrong treatment technology is an expensive error best discovered at bench and pilot scale, not after full-scale construction. Our treatability studies provide the empirical evidence required to select, optimise and confidently specify your process train.
We conduct jar testing, respirometry and continuous pilot trials to evaluate chemical dosing regimes, biological acclimatisation and physical separation efficiency against your actual wastewater. Each study answers specific engineering questions — can this biological process achieve <10 mg/L total nitrogen? what coagulant dose delivers the lowest sludge volume index? which membrane configuration holds flux under peak solids loading? The result is a technology recommendation underpinned by data, not assumption.
A pilot plant that runs without rigorous analytical validation produces anecdote, not engineering. Our process-analysis programme monitors chemical, physical and biological parameters through a combination of online instrumentation, composite sampling and accredited laboratory analysis.
We characterise influent variability, track removal efficiencies across each process stage, quantify chemical consumption and sludge production, and evaluate performance under deliberate stress — shock loads, temperature excursions and hydraulic surges. This produces a comprehensive mass balance and performance envelope that defines not only what the process achieves under ideal conditions, but how it behaves when operations deviate from design intent.
Translating pilot data into full-scale design requires more than simple dimensional scaling. Surface loading rates, mixing energy per unit volume, oxygen-transfer efficiency and solids residence time do not scale linearly; ignoring these dependencies leads to underperforming assets and costly retrofits.
Our scale-up methodology applies established engineering principles alongside empirical correlations derived from your pilot data. We generate design loadings, safety factors and equipment specifications that account for real-world variability, diurnal flow patterns and future capacity. We also optimise operating parameters — hydraulic retention time, sludge age, recirculation ratios and chemical set-points — to minimise lifecycle OPEX before your full-scale plant is even tendered.
When procuring proprietary equipment — membrane modules, UV reactors, dissolved air flotation units or advanced oxidation systems — vendor performance guarantees must be validated under your specific duty conditions, not merely in a clean-water factory test. We design and oversee equipment performance trials that subject proposed technologies to your actual wastewater chemistry, hydraulic loading and solids characteristics.
Our benchmarking protocols measure key indicators against specification: transmembrane pressure stability, UV dose delivery under UV-T variability, bubble-size distribution and rise velocity, or contaminant-destruction efficiency. We assess operability, maintenance accessibility and reliability under extended run conditions, giving you an objective comparison matrix to support final vendor selection and contract negotiation.
Data without interpretation is merely noise. Our reporting deliverables transform raw pilot data into structured engineering intelligence suitable for design teams, regulators and investment committees.
Each report presents statistical analysis of performance trends, validated mass balances, chemical and energy consumption benchmarks, and design recommendations with quantified uncertainty. We include CAPEX and OPEX estimates derived from actual pilot consumption data, together with regulatory-compliance documentation formatted for Environment Agency or SEPA permit applications. Where required, we present findings in workshop settings so your design engineers, operators and stakeholders share a common understanding of the results.
Our pilot testing programs evaluate all critical process parameters to ensure your full-scale system will perform as designed.
Wide Range of Pilot-Scale Treatment Technologies
1-10 m³/h capacity
0.5-5 m³/h capacity
0.1-2 m³/h capacity
0.5-10 m³/h capacity
1-20 m³/h capacity
Various configurations
Up to 100 kg/h
1-10 m³/h capacity
De-Risk Your Investment with Data-Driven Validation
Validate process performance before capital investment, avoiding costly design errors and ensuring your system will meet treatment objectives. See how pilot testing validated 94% TSS removal before full-scale DAF commitment →
Optimise chemical dosing, energy consumption, and operating parameters to minimise lifecycle costs and maximise project benefits. Run Process Efficiency Estimate →
Generate defensible data for permit applications and regulatory compliance, demonstrating your process will meet discharge requirements.
Deep understanding of water and wastewater treatment processes, ensuring pilot programs address real-world operational challenges.
Comprehensive data for full-scale system design including sizing, specifications, and operating parameters.
Pilot testing integrated with Reynolds & Bauhm equipment supply and engineering services for seamless project delivery.
Comprehensive Technical Resources
Explore detailed information about pilot testing methodologies, treatability studies, scale-up procedures, and best practices through our comprehensive technical resources.
Comprehensive guide to wastewater treatability testing, jar testing, and process selection methodology
Methodology for translating pilot results to full-scale design with scale-up factors and safety margins
Comparison of mobile and fixed pilot plant options, selection criteria, and deployment considerations
Protocols for validating equipment performance, benchmarking, and vendor comparison testing
Statistical analysis methods, report structure, and translating data into design specifications
Design guidelines, common pitfalls, quality assurance, and successful pilot program management
Custom pilot plant design, fabrication, installation, and commissioning for your specific process
Detailed performance analysis of chemical, physical, and advanced biological treatment parameters
Containerised and skid-mounted pilot plants for rapid on-site deployment and testing
Specialised test equipment for proprietary technology validation and unique process requirements
Complete Engineering Solutions
Complete piping and instrumentation diagram development based on pilot testing results.
View P&ID Design ServicesOptimise flow patterns and equipment performance with computational fluid dynamics.
Explore CFD SimulationDesign and implement control systems for your validated treatment process.
Explore SCADA & AutomationExpert assistance throughout your project lifecycle from pilot testing to commissioning.
Explore Technical SupportPackaged, containerised, skid-mounted and research-station families engineered for sites with no road, no grid, no operator and no local supply chain.
All five product families plus the engineering choices that span the catalogue — transport envelopes, off-grid power, satellite SCADA, swap-on-failure spares.
Read the HubComplete plants delivered as a single pre-commissioned package — villages, mining camps, expedition bases.
Read More10′, 20′ and 40′ ISO container plants hardened for hurricane, arctic, desert and salt-air environments.
Read MoreModular skids sized to helicopter sling-loads, 4×4 trailers and ATV sleds for sites with no road access.
Read MoreCustom-engineered pilots in skid-mounted, containerised, trailer-mounted and open-frame modular form factors — engineered around your specific treatability question, not adapted from a generic product.
All five form factors plus the engineering approach behind them.
Read the HubMost flexible; smallest transport unit for helicopter / 4×4 / light-truck access.
Read MoreWeatherproof, lockable, climate-controlled. Best for long or hostile campaigns.
Read MoreTen constraints that defeat remote pilots and the engineering responses to each.
Read MoreDownload our Pilot Testing Checklist (PDF, 450 KB) to prepare your site, define test objectives, and understand sampling requirements. Or request a custom test protocol tailored to your wastewater characteristics.
A well-conceived pilot programme is the highest-return investment you can make in a water-treatment project: it de-risks technology selection, validates regulatory compliance, generates credible design data and protects against the cost overruns and performance shortfalls that plague under-tested installations. Tell us your wastewater characteristics, treatment objectives and site constraints, and we will recommend the right pilot configuration, define a test protocol aligned to your decision milestones, and prepare a fixed-fee proposal with guaranteed deliverables.
Already have data? Run a process benefits estimate to quantify pilot project benefits.
Our expertise spans multiple industries with sector-specific water treatment solutions.