Process Development

Sedgman helps clients turn resource potential, process ideas and operational challenges into practical processing pathways. We combine metallurgical expertise, process engineering, modelling, testwork planning and scale-up insight to define options, validate assumptions and create a stronger technical basis for studies, engineering and long-term performance. 

Talk to Sedgman about your next process development challenge

Engineered process pathways that reduce technical uncertainty early. 

Process development is in our DNA. Sedgman helps clients move beyond early assumptions by building the evidence needed to understand ore behaviour, evaluate processing options, define performance criteria and identify the pathway most likely to deliver value in practice.

Our teams connect metallurgical testwork planning, process simulation, flowsheet development, unit operation selection, pilot programs, scale-up design, reagent and chemical selection, and specialist modelling across minerals, critical minerals, brines, energy and chemicals sectors. This work helps establish decision-grade inputs that later study, engineering and delivery phases depend on.

By combining technical depth with practical delivery and operating insight, Sedgman helps clients reduce technical risk before it is locked in. The result is a clearer processing basis, stronger confidence in recovery and product quality, and a more dependable route into concept studies, feasibility, detailed engineering, commissioning and optimisation.

Outcomes We Focus On 

  • Faster definition of processing route options and preferred development pathways.
  • Reduced technical uncertainty before study, engineering and investment decisions advance.
  • Improved recovery, product quality, operability and scale-up confidence.
  • Better-informed capital, operating and sustainability decision inputs.

What We Deliver 

We define targeted testwork programs that generate the right evidence at the right stage. From orebody and metallurgical testwork planning through to laboratory and pilot program oversight, we help clients build confidence in the selected process route and the decisions that follow. 

We develop and refine process flowsheets using simulation, modelling and engineering judgement to evaluate options, understand sensitivities and strengthen the basis for process selection, design progression and investment decisions. 

We help select and define unit operations, equipment requirements and performance criteria so processing solutions are measurable, scalable and aligned with recovery, quality, operability and commercial objectives. 

Where greater certainty is required, we support demonstration programs, pilot plants and scale-up design to bridge the gap between concept and commercial operation. Our teams help turn promising ideas into practical, validated pathways to delivery. 

We target testwork to support reagent and chemical selection to improve recovery, product quality, operating efficiency and downstream performance, while considering the practical and commercial impacts of chemical consumption and handling. 

Our specialist process capability extends to solution mining, brine recovery, pond modelling and pilot programs, helping clients understand fluid chemistry, evaporation, recovery and system performance earlier in the development pathway. 

We assess tailings, water and effluent treatment requirements as part of process development so environmental, operational and sustainability considerations are built into the processing pathway from the start. 

Process Definition and Flowsheet Development

Process Definition and Flowsheet Development

Make confident processing decisions from the start.

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Pilot, Scale-up and Process Performance 

Pilot, Scale-up and Process Performance 

Proven pathways from testwork to performance-ready design. 

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Brine, Pond and Tailings Water Solutions 

Brine, Pond and Tailings Water Solutions 

Model, recover and manage complex brine and process water systems with confidence. 

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