Process Modelling

Mathematical modelling of physical, chemical and thermodynamic processes for plant design and optimisation
Steady-state mass and energy balances are used at all stages of the project life-cycle as the basis for flowsheet development, equipment sizing and process optimisation. We offer steady-state modelling in METSIM® to any level of detail – desktop study through to detailed design. Typical processes modelled include comminution, flotation, leaching, solid-liquid separation, precious metal recovery, base-metal solution purification and recovery, reagent regeneration and effluent treatment.
Dynamic simulation is used to understand and quantify process behaviour through time during periods of change. Examples of cases that benefit from dynamic simulation are:

  • Batch and semi-batch processes operating on the main production stream, such as a heap leach, impacting the ability to forecast production and plan future cycles
  • Interstage surge capacity design for processes with significantly different levels of utilisation across stages
  • Hazardous reactor behaviour under certain conditions, such as highly exothermic reactors dependant on automatic temperature control during start-up
  • Rapidly changing inputs or loads, such as extreme weather impacting a site water balance, or sunlight incidence and power demand impacting a solar thermochemical power generation process

We offer dynamic modelling in ITHACA®, our flagship software product. ITHACA allows the user to model a flow-sheet complete with multi-phase chemistry, process control, variable operating modes and discrete events.

Other Services


Process review, plant troubleshooting, metallurgical accounting and testwork program design.

Process Engineering

Process design, capital and operating cost estimation, due diligence and trade-off studies.

Digital Twin Solutions

Computer simulation of operating plants to forecast process behaviour and outcomes.

Contact Us

PO Box 360, Blackheath NSW 2785