Steven P Suthers | CSIRO (original) (raw)

Papers by Steven P Suthers

With increased emphasis on reducing costs and carbon emissions in mineral processing, it is becom... more With increased emphasis on reducing costs and carbon emissions in mineral processing, it is becoming essential to employ the most efficient comminution devices and to use them to maximum effect. High pressure grinding rolls (HPGR) are considered highly efficient compared with other devices, however their relative efficiency in multi-HPGR circuits is less well understood. A series of comminution tests was carried out to evaluate three multi-pass HPGR circuits and a jaw crusher-ball mill circuit. Combinations of HPGR units (1.0 m and 0.25 m diameter), jaw crushers and Bond ball mills were used to grind a 32 mm top size porphyry copper feed (BBWI = 12.1) to a product P80 size of about 150 μm. Up to three passes of HPGR were used in each circuit, with energy measurement and size analysis at each point in the comminution process. The energy efficiencies of individual comminution stages and of the overall circuits were quantified and evaluated using three different approaches. The operati...

With increased emphasis on reducing costs and carbon emissions in mineral processing, it is becom... more With increased emphasis on reducing costs and carbon emissions in mineral processing, it is becoming essential to employ the most efficient comminution devices and to use them to maximum effect. High pressure grinding rolls (HPGR) are considered highly efficient compared with other devices, however their relative efficiency in multi-HPGR circuits is less well understood. A series of comminution tests was carried out to evaluate three multi-pass HPGR circuits and a jaw crusher-ball mill circuit. Combinations of HPGR units (1.0 m and 0.25 m diameter), jaw crushers and Bond ball mills were used to grind a 32 mm top size porphyry copper feed (BBWI = 12.1) to a product P80 size of about 150 μm. Up to three passes of HPGR were used in each circuit, with energy measurement and size analysis at each point in the comminution process. The energy efficiencies of individual comminution stages and of the overall circuits were quantified and evaluated using three different approaches. The operati...

Mineral Processing and Extractive Metallurgy Review, 2019

Techniques for dry processing low-grade iron ores and tailings are being investigated. Dry deslim... more Techniques for dry processing low-grade iron ores and tailings are being investigated. Dry desliming tests using a rotating wheel air classifier and factorial design were performed on a difficult-to-treat lowgrade high-goethite Australian iron ore tailings. The results were compared with theoretically ideal size separation and a hydrocyclone desliming study using the same tailings. The air classifier performance was poorer than the hydrocyclone due to agglomerated particles in the feed, including fines coating coarser particles. The "fish hook" effect was observed and discussed. After dry desliming, the silica and alumina contents of a selected product were 30% and 26% lower, respectively.

Minerals Engineering, 2015

CEON check, has decided to make the necessary corrections and publish the ERRATUM of the paper du... more CEON check, has decided to make the necessary corrections and publish the ERRATUM of the paper due to an unintentional mistake of omitting a cited reference for two figures and a table during the process of preparing for publication. ERRATUM Chapter 5 "HPGR Results" was corrected as following: a) In the title of Figure 3, the cited reference was introduced under the number 17; b) In the title of Figure 4, the cited reference was introduced under the number 17; c) In the title of Table 1, the cited reference was introduced under the number 17.

JOM, 2000

Quantitative microscopy using scanning electron microscopy-based automatic measurement methods an... more Quantitative microscopy using scanning electron microscopy-based automatic measurement methods and data-processing techniques that provide broad ranges of applications is very popular in the mining industry. These systems determine the quantities and microtextures of the ore samples and metallurgical products to guide process development and troubleshoot processing problems.

International Journal of Mineral Processing, 2008

A new modelling technique for simulating hydrocyclone performance has been developed, in which pa... more A new modelling technique for simulating hydrocyclone performance has been developed, in which particles in every size fraction of the feed ore are classified based on ore texture type, taking into account that the same ore texture types in every size fraction of the feed ore have similar mineral contents and densities. Mineral tracking by optical image analysis and newly-developed texture classification software was used in this technique to classify the feed ore particles by texture type and to determine the average particle density of each class in every size fraction. Particle density calculations took into account the reduction of porosity with reduction of particle size and the effect of different imaging magnifications for different size fractions. The data obtained about each class in every size fraction was used to create a virtual feed which was input to the hydrocyclone model to simulate the ore processing performance. For model validation, pilot-scale hydrocyclone beneficiation experiments were performed on an iron ore blend, using different hydrocyclone pressures and percent solids in the feed pulp. Model parameters were determined from one set of experimental results and the calibrated model was then used to predict the outcomes of the two subsequent experiments. Comparisons of the model and experimental results are presented and discussed. This new approach enables prediction of the recovery of each mineral and texture type in the products, calculation of the total product iron grade and recovery, and optimisation of the hydrocyclone performance for a given ore.

Mineral Processing and Extractive Metallurgy, 2014

Minerals Engineering, 2016

Minerals Engineering, 2007

Minerals Engineering, 2007

Mineral Processing and Extractive Metallurgy Review, 2019

Techniques for dry processing low-grade iron ores and tailings are being investigated. Dry deslim... more Techniques for dry processing low-grade iron ores and tailings are being investigated. Dry desliming tests using a rotating wheel air classifier and factorial design were performed on a difficult-to-treat low-grade high-goethite Australian iron ore tailings. The results were compared with theoretically ideal size separation and a hydrocyclone desliming study using the same tailings. The air classifier performance was poorer than the hydrocyclone due to agglomerated particles in the feed, including fines coating coarser particles. The “fish hook” effect was observed and discussed. After dry desliming, the silica and alumina contents of a selected product were 30% and 26% lower, respectively.

are the QEM*SEM image analysis team at CSIRO Minerals. For more information, contact B. Jenkins, ... more are the QEM*SEM image analysis team at CSIRO Minerals. For more information, contact B. Jenkins, Process Mineralogy, CSIRO Minerals, Queensland Center for Advanced Technologies, 2643 Moggill Road, Pinjarra Hills, Qld 4069 Australia; telephone 61 7 3212 4410; fax 61 7 3212; e-mail b.jenkins@cat.csiro.au.

GeoMet 2016

The mining industry is constantly seeking methods for optimising the exploitation of mineral reso... more The mining industry is constantly seeking methods for optimising the exploitation of mineral resources, such as iron ore, in a sustainable and eco-efficient manner for economic and social benefit. When faced with resources that have mineralogical or textural complexity, poorer grades
or geological variability, it is particularly important to apply a comprehensive geometallurgical approach to the development of the mining operation, from resource definition through to processed product. Integral to this approach is the quantitative characterisation of representative samples across the whole orebody.

A key factor that associates the geological characteristics of iron ores to their processing response is ore texture. While the classification of samples on the basis of chemical or physical properties alone is often not sufficient to predict their processing behaviour, classification and quantification of texture types can be effectively correlated to metallurgical performance in processes such as blending, beneficiation, pellet making, sintering and ironmaking. This paper describes some
of the research conducted by CSIRO pertaining to the design and rationale of a texture-based classification system for Australian iron ores; some of the tools developed and used to apply such classification; and the application of the generated data to quantifying, modelling and predicting sintering behaviour and performance in the blast furnace.

Proceedings of Automated Mineralogy 2006, 2006

Optical image analysis is a very convenient tool for obtaining comprehensive information about fi... more Optical image analysis is a very convenient tool for obtaining comprehensive information about fine iron ore size fractions. Data can be obtained on mineral abundances, porosity, particle shape and ore textures with a high level of accuracy. A range of techniques has been used to characterise iron ore samples on a particle-by-particle basis. Automatic textural classification of iron ore particles was used to establish classes containing particles with very similar mineral composition and texture. Image analysis coupled with probe analysis and mineral density measurements provided information about the chemical composition and density of each particle class. The combination of these results enabled a “virtual feed” to be created, which can be a key input into a beneficiation unit model for predicting its performance. Identification and classification of the textural type of each particle was performed according to the CSIRO-Hamersley Iron Ore Group Classification Scheme. If more detailed classification is needed, further classification can be performed based on dimensional, chemical or mineral criteria, such as the presence of certain minerals in particles or total iron content. Some deficiencies of the current image analysis procedures and their further improvement and automation are also discussed.

Optical image analysis is a very convenient tool for obtaining comprehensive information about fi... more Optical image analysis is a very convenient tool for obtaining comprehensive information about fine iron ore size fractions. Data can be obtained on mineral abundances, porosity, particle shape and ore textures with a high level of accuracy. A range of techniques has been used to characterise iron ore samples on a particle-by-particle basis. Automatic textural classification of iron ore particles was used to establish classes containing particles with very similar mineral composition and texture. Image analysis coupled with probe analysis and mineral density measurements provided information about the chemical composition and density of each particle class. The combination of these results enabled a ''virtual feed'' to be created, which can be a key input into a beneficiation unit model for predicting its performance. Identification and classification of the textural type of each particle was performed according to the CSIRO-Hamersley Iron Ore Group Classification Scheme. If more detailed classification is needed, further classification can be performed based on dimensional, chemical or mineral criteria, such as the presence of certain minerals in particles or total iron content. Some deficiencies of the current image analysis procedures and their further improvement and automation are also discussed.

The Fifth Baosteel Biennial Academic Conference 2013, 2013

CSIRO tested a Crosslands Resources (“CRL”) concentrate sample. It was predominantly magnetite an... more CSIRO tested a Crosslands Resources (“CRL”) concentrate sample. It was predominantly magnetite and very high in Fe, and moderately low in SiO2 with extremely low levels of deleterious impurities, such as S, Ti, Cu and Al2O3. It therefore meets the chemistry targets of magnetite concentrates for making both blast furnace and DR (direct reduction) pellets and is considerably better than the typical chemistry of sinter feeds commercially available on the market. However at about 80% passing 75 microns and with a relatively low specific surface area of ~761 cm2/g, it is a bit coarser than most pellet feeds and much finer than normal sinter feeds. Accordingly, special strategies are required in order to utilise it at high proportions in pelletising and sintering. This paper discusses various raw material preparation technologies and blending optimization methods demonstrated to be effective for improving the sintering and pelletising performance of CRL magnetite concentrate. Pre-granualtion and addition of hydrated lime were found to be particularly efficient in recovering the sintering productivity of sinter blends containing up to 15-20% CRL pellet feed. In pelletising, HPGR (high pressure grinding roll) grinding enables production of good quality pellets from 100% CRL concentrate and optimized blends containing up to70% CRL concentrate also form good pellets.

Beneficiation of -2 mm low-grade iron ore tailings (50.7% Fe, 10.8% SiO2 and 4.4% Al2O3) from Wes... more Beneficiation of -2 mm low-grade iron ore tailings (50.7% Fe, 10.8% SiO2 and 4.4% Al2O3) from Western Australia was studied. The sample consisted of hydrohematite, goethite and quartz, with lesser kaolinite and shale. Two processing options were tested, being wet high-intensity magnetic separation (WHIMS) either using deslimed or untreated feed, and reduction (magnetising) roasting of deslimed feed followed by Davis tube tests. WHIMS tests using deslimed feed gave a product having 55.4% Fe, 6.1% SiO2 and 2.7% Al2O3, while the iron recovery was 55.7%. The calcined iron grade was 62.1% Fe. Davis tube tests using deslimed feed that had been reduction roasted at 700°C using a 1:1 mixture of CO/CO2 gave a product with 63.2% Fe, 5.4% SiO2 and 2.9% Al2O3, while the iron recovery was 60.1%. Overall, desliming followed by reduction roasting and Davis tube tests produced the highest grade product with the highest iron recovery.

Metallurgical Plant Design and Operating Strategies, Proceedings (MetPlant 2004), 2004

The ability to design a beneficiation process for a new orebody based on particular feed characte... more The ability to design a beneficiation process for a new orebody based on particular feed characteristics is a powerful and practical tool. A new technique has been developed where beneficiation outcomes can be calculated by combining feed size-by-size chemical analysis, mineralogy, liberation and particle characteristics with a series of simple theoretical unit separation models rather than a simple mass balance approach or an exhaustive beneficiation test program. The new technique provides the ability to rapidly identify ore types that have the potential to meet product specifications whilst also rejecting others that will not meet specification even if a perfect separation was achieved. Beyond the broad scale decision making process, practical mineral separation curves from actual plant data can be used to more closely simulate the proposed process. This approach reduces the amount of laboratory and pilot plant work necessary by targeting what process stages will be required, increases early rejection of uneconomic options, identifies problematic ore types or unit operations and is a step towards estimation of final grade and recoveries achievable in potential circuit configurations. Examples are given for iron ore fines, where modelling predictions identified ores that would never reach target product grade, those that could be used for blending and those that were economic. The predicted outcomes of grade and recovery for a deposit composite are compared against actual test results using beneficiation processes such as grinding, desliming, magnetic separation and reverse flotation. A practical process configuration which achieved target iron grade and recovery was successfully determined during the testwork, guided by modelling results, whereas previous laboratory pilot plant trials were unsuccessful. The method can be equally applied to flow sheet development in plant design for heavy minerals sands, base and precious metals.

With increased emphasis on reducing costs and carbon emissions in mineral processing, it is becom... more With increased emphasis on reducing costs and carbon emissions in mineral processing, it is becoming essential to employ the most efficient comminution devices and to use them to maximum effect. High pressure grinding rolls (HPGR) are considered highly efficient compared with other devices, however their relative efficiency in multi-HPGR circuits is less well understood. A series of comminution tests was carried out to evaluate three multi-pass HPGR circuits and a jaw crusher-ball mill circuit. Combinations of HPGR units (1.0 m and 0.25 m diameter), jaw crushers and Bond ball mills were used to grind a 32 mm top size porphyry copper feed (BBWI = 12.1) to a product P80 size of about 150 μm. Up to three passes of HPGR were used in each circuit, with energy measurement and size analysis at each point in the comminution process. The energy efficiencies of individual comminution stages and of the overall circuits were quantified and evaluated using three different approaches. The operati...

With increased emphasis on reducing costs and carbon emissions in mineral processing, it is becom... more With increased emphasis on reducing costs and carbon emissions in mineral processing, it is becoming essential to employ the most efficient comminution devices and to use them to maximum effect. High pressure grinding rolls (HPGR) are considered highly efficient compared with other devices, however their relative efficiency in multi-HPGR circuits is less well understood. A series of comminution tests was carried out to evaluate three multi-pass HPGR circuits and a jaw crusher-ball mill circuit. Combinations of HPGR units (1.0 m and 0.25 m diameter), jaw crushers and Bond ball mills were used to grind a 32 mm top size porphyry copper feed (BBWI = 12.1) to a product P80 size of about 150 μm. Up to three passes of HPGR were used in each circuit, with energy measurement and size analysis at each point in the comminution process. The energy efficiencies of individual comminution stages and of the overall circuits were quantified and evaluated using three different approaches. The operati...

Mineral Processing and Extractive Metallurgy Review, 2019

Techniques for dry processing low-grade iron ores and tailings are being investigated. Dry deslim... more Techniques for dry processing low-grade iron ores and tailings are being investigated. Dry desliming tests using a rotating wheel air classifier and factorial design were performed on a difficult-to-treat lowgrade high-goethite Australian iron ore tailings. The results were compared with theoretically ideal size separation and a hydrocyclone desliming study using the same tailings. The air classifier performance was poorer than the hydrocyclone due to agglomerated particles in the feed, including fines coating coarser particles. The "fish hook" effect was observed and discussed. After dry desliming, the silica and alumina contents of a selected product were 30% and 26% lower, respectively.

Minerals Engineering, 2015

CEON check, has decided to make the necessary corrections and publish the ERRATUM of the paper du... more CEON check, has decided to make the necessary corrections and publish the ERRATUM of the paper due to an unintentional mistake of omitting a cited reference for two figures and a table during the process of preparing for publication. ERRATUM Chapter 5 "HPGR Results" was corrected as following: a) In the title of Figure 3, the cited reference was introduced under the number 17; b) In the title of Figure 4, the cited reference was introduced under the number 17; c) In the title of Table 1, the cited reference was introduced under the number 17.

JOM, 2000

Quantitative microscopy using scanning electron microscopy-based automatic measurement methods an... more Quantitative microscopy using scanning electron microscopy-based automatic measurement methods and data-processing techniques that provide broad ranges of applications is very popular in the mining industry. These systems determine the quantities and microtextures of the ore samples and metallurgical products to guide process development and troubleshoot processing problems.

International Journal of Mineral Processing, 2008

A new modelling technique for simulating hydrocyclone performance has been developed, in which pa... more A new modelling technique for simulating hydrocyclone performance has been developed, in which particles in every size fraction of the feed ore are classified based on ore texture type, taking into account that the same ore texture types in every size fraction of the feed ore have similar mineral contents and densities. Mineral tracking by optical image analysis and newly-developed texture classification software was used in this technique to classify the feed ore particles by texture type and to determine the average particle density of each class in every size fraction. Particle density calculations took into account the reduction of porosity with reduction of particle size and the effect of different imaging magnifications for different size fractions. The data obtained about each class in every size fraction was used to create a virtual feed which was input to the hydrocyclone model to simulate the ore processing performance. For model validation, pilot-scale hydrocyclone beneficiation experiments were performed on an iron ore blend, using different hydrocyclone pressures and percent solids in the feed pulp. Model parameters were determined from one set of experimental results and the calibrated model was then used to predict the outcomes of the two subsequent experiments. Comparisons of the model and experimental results are presented and discussed. This new approach enables prediction of the recovery of each mineral and texture type in the products, calculation of the total product iron grade and recovery, and optimisation of the hydrocyclone performance for a given ore.

Mineral Processing and Extractive Metallurgy, 2014

Minerals Engineering, 2016

Minerals Engineering, 2007

Minerals Engineering, 2007

Mineral Processing and Extractive Metallurgy Review, 2019

Techniques for dry processing low-grade iron ores and tailings are being investigated. Dry deslim... more Techniques for dry processing low-grade iron ores and tailings are being investigated. Dry desliming tests using a rotating wheel air classifier and factorial design were performed on a difficult-to-treat low-grade high-goethite Australian iron ore tailings. The results were compared with theoretically ideal size separation and a hydrocyclone desliming study using the same tailings. The air classifier performance was poorer than the hydrocyclone due to agglomerated particles in the feed, including fines coating coarser particles. The “fish hook” effect was observed and discussed. After dry desliming, the silica and alumina contents of a selected product were 30% and 26% lower, respectively.

are the QEM*SEM image analysis team at CSIRO Minerals. For more information, contact B. Jenkins, ... more are the QEM*SEM image analysis team at CSIRO Minerals. For more information, contact B. Jenkins, Process Mineralogy, CSIRO Minerals, Queensland Center for Advanced Technologies, 2643 Moggill Road, Pinjarra Hills, Qld 4069 Australia; telephone 61 7 3212 4410; fax 61 7 3212; e-mail b.jenkins@cat.csiro.au.

GeoMet 2016

The mining industry is constantly seeking methods for optimising the exploitation of mineral reso... more The mining industry is constantly seeking methods for optimising the exploitation of mineral resources, such as iron ore, in a sustainable and eco-efficient manner for economic and social benefit. When faced with resources that have mineralogical or textural complexity, poorer grades
or geological variability, it is particularly important to apply a comprehensive geometallurgical approach to the development of the mining operation, from resource definition through to processed product. Integral to this approach is the quantitative characterisation of representative samples across the whole orebody.

A key factor that associates the geological characteristics of iron ores to their processing response is ore texture. While the classification of samples on the basis of chemical or physical properties alone is often not sufficient to predict their processing behaviour, classification and quantification of texture types can be effectively correlated to metallurgical performance in processes such as blending, beneficiation, pellet making, sintering and ironmaking. This paper describes some
of the research conducted by CSIRO pertaining to the design and rationale of a texture-based classification system for Australian iron ores; some of the tools developed and used to apply such classification; and the application of the generated data to quantifying, modelling and predicting sintering behaviour and performance in the blast furnace.

Proceedings of Automated Mineralogy 2006, 2006

Optical image analysis is a very convenient tool for obtaining comprehensive information about fi... more Optical image analysis is a very convenient tool for obtaining comprehensive information about fine iron ore size fractions. Data can be obtained on mineral abundances, porosity, particle shape and ore textures with a high level of accuracy. A range of techniques has been used to characterise iron ore samples on a particle-by-particle basis. Automatic textural classification of iron ore particles was used to establish classes containing particles with very similar mineral composition and texture. Image analysis coupled with probe analysis and mineral density measurements provided information about the chemical composition and density of each particle class. The combination of these results enabled a “virtual feed” to be created, which can be a key input into a beneficiation unit model for predicting its performance. Identification and classification of the textural type of each particle was performed according to the CSIRO-Hamersley Iron Ore Group Classification Scheme. If more detailed classification is needed, further classification can be performed based on dimensional, chemical or mineral criteria, such as the presence of certain minerals in particles or total iron content. Some deficiencies of the current image analysis procedures and their further improvement and automation are also discussed.

Optical image analysis is a very convenient tool for obtaining comprehensive information about fi... more Optical image analysis is a very convenient tool for obtaining comprehensive information about fine iron ore size fractions. Data can be obtained on mineral abundances, porosity, particle shape and ore textures with a high level of accuracy. A range of techniques has been used to characterise iron ore samples on a particle-by-particle basis. Automatic textural classification of iron ore particles was used to establish classes containing particles with very similar mineral composition and texture. Image analysis coupled with probe analysis and mineral density measurements provided information about the chemical composition and density of each particle class. The combination of these results enabled a ''virtual feed'' to be created, which can be a key input into a beneficiation unit model for predicting its performance. Identification and classification of the textural type of each particle was performed according to the CSIRO-Hamersley Iron Ore Group Classification Scheme. If more detailed classification is needed, further classification can be performed based on dimensional, chemical or mineral criteria, such as the presence of certain minerals in particles or total iron content. Some deficiencies of the current image analysis procedures and their further improvement and automation are also discussed.

The Fifth Baosteel Biennial Academic Conference 2013, 2013

CSIRO tested a Crosslands Resources (“CRL”) concentrate sample. It was predominantly magnetite an... more CSIRO tested a Crosslands Resources (“CRL”) concentrate sample. It was predominantly magnetite and very high in Fe, and moderately low in SiO2 with extremely low levels of deleterious impurities, such as S, Ti, Cu and Al2O3. It therefore meets the chemistry targets of magnetite concentrates for making both blast furnace and DR (direct reduction) pellets and is considerably better than the typical chemistry of sinter feeds commercially available on the market. However at about 80% passing 75 microns and with a relatively low specific surface area of ~761 cm2/g, it is a bit coarser than most pellet feeds and much finer than normal sinter feeds. Accordingly, special strategies are required in order to utilise it at high proportions in pelletising and sintering. This paper discusses various raw material preparation technologies and blending optimization methods demonstrated to be effective for improving the sintering and pelletising performance of CRL magnetite concentrate. Pre-granualtion and addition of hydrated lime were found to be particularly efficient in recovering the sintering productivity of sinter blends containing up to 15-20% CRL pellet feed. In pelletising, HPGR (high pressure grinding roll) grinding enables production of good quality pellets from 100% CRL concentrate and optimized blends containing up to70% CRL concentrate also form good pellets.

Beneficiation of -2 mm low-grade iron ore tailings (50.7% Fe, 10.8% SiO2 and 4.4% Al2O3) from Wes... more Beneficiation of -2 mm low-grade iron ore tailings (50.7% Fe, 10.8% SiO2 and 4.4% Al2O3) from Western Australia was studied. The sample consisted of hydrohematite, goethite and quartz, with lesser kaolinite and shale. Two processing options were tested, being wet high-intensity magnetic separation (WHIMS) either using deslimed or untreated feed, and reduction (magnetising) roasting of deslimed feed followed by Davis tube tests. WHIMS tests using deslimed feed gave a product having 55.4% Fe, 6.1% SiO2 and 2.7% Al2O3, while the iron recovery was 55.7%. The calcined iron grade was 62.1% Fe. Davis tube tests using deslimed feed that had been reduction roasted at 700°C using a 1:1 mixture of CO/CO2 gave a product with 63.2% Fe, 5.4% SiO2 and 2.9% Al2O3, while the iron recovery was 60.1%. Overall, desliming followed by reduction roasting and Davis tube tests produced the highest grade product with the highest iron recovery.

Metallurgical Plant Design and Operating Strategies, Proceedings (MetPlant 2004), 2004

The ability to design a beneficiation process for a new orebody based on particular feed characte... more The ability to design a beneficiation process for a new orebody based on particular feed characteristics is a powerful and practical tool. A new technique has been developed where beneficiation outcomes can be calculated by combining feed size-by-size chemical analysis, mineralogy, liberation and particle characteristics with a series of simple theoretical unit separation models rather than a simple mass balance approach or an exhaustive beneficiation test program. The new technique provides the ability to rapidly identify ore types that have the potential to meet product specifications whilst also rejecting others that will not meet specification even if a perfect separation was achieved. Beyond the broad scale decision making process, practical mineral separation curves from actual plant data can be used to more closely simulate the proposed process. This approach reduces the amount of laboratory and pilot plant work necessary by targeting what process stages will be required, increases early rejection of uneconomic options, identifies problematic ore types or unit operations and is a step towards estimation of final grade and recoveries achievable in potential circuit configurations. Examples are given for iron ore fines, where modelling predictions identified ores that would never reach target product grade, those that could be used for blending and those that were economic. The predicted outcomes of grade and recovery for a deposit composite are compared against actual test results using beneficiation processes such as grinding, desliming, magnetic separation and reverse flotation. A practical process configuration which achieved target iron grade and recovery was successfully determined during the testwork, guided by modelling results, whereas previous laboratory pilot plant trials were unsuccessful. The method can be equally applied to flow sheet development in plant design for heavy minerals sands, base and precious metals.