Bitumen Scale-Up: Engineering Challenges in Vacuum Distillation (Part 1)
What happens when the feedstock you receive is completely different from what you designed for?
In our line of work, we often say that industrial R&D is never just about the calculations you do in the office - it’s about how you adapt when the process fails the moment you press "Start."
One of our past projects involved scaling up bitumen production using a pilot vacuum distillation unit. We were operating under a tight 6-week deadline with a solid technical plan, but the project took an unexpected turn the moment the material arrived. Instead of a pumpable liquid, we received a feedstock that was completely solid at room temperature.
Suddenly, the primary engineering challenge shifted: it wasn't just about the distillation anymore - it was about keeping the entire line from freezing, even at 100°C.
I’m Dmitry, and I wanted to share a behind-the-scenes look at how our team handled this challenge. We documented the entire journey to show the reality of our work: the technical setbacks, the rapid on-site modifications, and the field brainstorming that kept the project on track.
This is Part 1 of a 3-part case study series where I break down the initial project launch, the unit reassembly, and the start-up phase.
If you’re interested in process engineering, unit design, or the reality of pilot-scale R&D, I hope you find this breakdown useful.
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