Treating the pilot as a demonstration only
A pilot should generate data for engineering decisions. If the test plan does not answer scale-up questions, the pilot may look successful while still leaving the project unready.
Ignoring impurities and variability
Feed variability, impurity behaviour and off-spec cases often drive equipment selection, control strategy, washing, filtration, emissions and waste handling.
Underestimating utilities
Heat, cooling, compressed air, power, nitrogen, water and wastewater can become major constraints when moving from lab or pilot to industrial scale.
Starting commissioning too late
First-of-a-kind plants need structured startup planning, test logic, operating procedures and safety review long before mechanical completion.