Process Definition and Flowsheet Development

Our experts provide data-driven insights into how an orebody will behave, which processing options are viable and where value can be maximized. By combining targeted metallurgical testwork, process simulation, flowsheet development and practical engineering expertise, we translate resource knowledge into processing strategies that can be evaluated, engineered, delivered and operated with greater confidence.

Strong processing decisions start with evidence. Sedgman works with clients to define how an orebody or raw material should be tested, modelled and translated into a practical processing solution, providing the technical clarity needed before major study, engineering and investment decisions are made.

No two orebodies are the same, and even deposits with similar characteristics can respond differently to processing. Our specialists combine metallurgical testwork planning, process simulation, flowsheet development and unit operation selection across bulk minerals, precious and base metals, industrial minerals, critical new economy minerals, and energy and chemicals. This breadth of experience enables Sedgman to transfer proven methodologies, technologies and operating insights between industries, helping clients access innovative solutions shaped by lessons learned across diverse resource processing sectors. For resource projects, this brings ore characteristics, recovery objectives, product quality requirements, equipment constraints and operability considerations into a structured process development approach. For downstream processing, energy and chemical projects, we combine raw material quality insights, targeted testwork, and process simulation to define process solutions that will meet product quality, performance and commercial objectives.

By combining trusted metallurgical and chemical processing expertise with modern simulation and modelling capability and practical delivery experience, Sedgman helps clients test assumptions early, compare alternatives and select a path that can stand up technically and commercially. Unlike stand-alone testing organisations, Sedgman translates testwork outcomes into integrated process solutions that consider engineering, constructability, operations, maintenance and long-term asset performance. This enables clients to move beyond data generation and make confident investment decisions based on practical, executable processing strategies. Our focus is on identifying solutions that are practical and aligned with project value drivers. The result is a stronger foundation for concept development, feasibility studies, detailed engineering and long-term operational performance.

Sedgman’s process development specialists operate within a business that designs, delivers, operates and optimises processing facilities. This unique lifecycle perspective enables process decisions to be tested against real-world engineering, construction and operational requirements well before major capital commitments are made.

Outcomes We Focus On

Business Outcomes:

  • Reduced technical and execution risk prior to major investment decisions.
  • Improved confidence in project economics and development pathways.
  • Increased certainty around production performance, recovery and product quality.
  • Better-informed capital allocation decisions through techno-economic evaluation.
  • Reduced scale-up and technology adoption risk.
  • Improved long-term operating performance and asset value.

Technical Outcomes:

  • Better understanding of material behavior and process responses.
  • More robust flowsheets and unit operation selection.
  • Improved engineering design basis and performance criteria.
  • Scalable process solutions, supported by modelling, piloting and testwork.
  • Stronger foundations for feasibility studies, engineering and delivery.

What We Deliver

We design and manage targeted testwork programs that produce the evidence needed for process definition. Recognising that no two orebodies are exactly alike, our approach considers ore variability, mineralogy, liberation, comminution performance, separation behaviour and hydrometallurgical response across the mine plan so testwork is focused on decisions that matter to recovery, product quality, cost and project risk.

For emerging technologies and novel process routes, we develop stages testwork, piloting and validation programs designed to reduce scale-up uncertainty and improve confidence that laboratory and pilot outcomes can be translated into commercial-scale performance.

We use process simulation and modelling to evaluate processing options, test sensitivities and strengthen the assumptions behind mass balance, water balance, energy balance and performance criteria. This includes integrated process modelling, mine-to-mill and ore pre-concentration assessment where relevant, and the use of specialist modelling tools such as METSIM and PHREEQc, SysCAD, Bruno (Metso), LIMN, and IES extraction simulator.

Advanced modelling allows clients to evaluate multiple scenarios before committing capital, providing greater visibility into performance sensitivities, process risks and optimization opportunities. This data-driven approach helps reduce uncertainty and improve confidence in study outcomes and project decisions.

We develop flowsheets that translate testwork results and modelling outputs into practical processing aligned with project objectives. Our teams assess circuit alternatives, operating parameters, recycle streams, water and materials handling interfaces, recovery and product quality trade-offs, and opportunities to simplify the path from resource to product – all with final operability and project economics in mind. Sustainability considerations form part of our process development approach, with evaluation of energy efficiency, water consumption, tailings generation, reagent utilisation, emissions intensity and opportunities for resource recovery integrated into option assessments wherever relevant. Drawing upon experience supporting operational assets, we evaluate maintainability, operational complexity, process stability, workforce requirements and long-term reliability during flowsheet development to help avoid costly downstream challenges.

We bring expertise across the full processing value chain, including comminution, mineral processing, hydrometallurgy and pyrometallurgy, allowing us to select unit operations that align with project objectives, ore characteristics and operating requirements.

Our expertise includes crushing, screening and classification; dense media, gravity, magnetic and electromagnetic separation; flotation, including conventional and coarse particle flotation; leaching, solvent extraction and electrowinning; evaporation and crystallisation. We also provide expertise in dewatering, thickening and filtration; agglomeration, calcination, roasting, drying and related thermal processing steps; tailings handling, residue management, materials handling and product loadout.

We support thorough review and testing of novel equipment to support evaluation against typical approaches and engage with OEMs to support integration into flowsheets, helping clients incorporate the most appropriate technologies into their process flowsheets with confidence.

Our recommendations are based on independent assessment of performance, operability, lifecycle cost and project objectives. We work with equipment vendors and technology providers throughout evaluation processes while maintaining a technology-agnostic approach focused on achieving the best overall project outcome.

Process selection decisions have significant impacts on capital intensity, operating costs, recovery outcomes, environmental performance and project value. Sedgman evaluates technical alternatives through a techno-economic lens, helping clients understand the trade-offs between competing options and identify the processing pathway that maximizes long-term project value.

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