What we do

Process Development and Optimisation:
Maximise efficiencies and
minimise costs consistently

With process design, modelling, development and optimisation experience spanning various industries, plant types, commodities and products, our process engineers will unlock the chemistry or metallurgy, then save you time and money in identifying and implementing the ideal process and workflow.

Process development and optimisation

What we do

The success of minerals and chemical projects revolves around process development and optimisation. We arguably have some of the best teams in the world working with clients around the globe. We have the process development and optimisation expertise and modelling capabilities in-house to take a greenfield project from concept through to design and build.

Alternatively, we can consult on process issues with existing flowsheets and operations, minimising capital outlay, operating costs and risk, while maximising efficiencies, safety, performance and profitability.

Our process development and process optimisation capabilities span the process value chain, including.

  • Process design, simulation and analysis
  • Process optimisation and troubleshooting
  • Aspen Plus® Process Modelling
  • Flowsheet development
  • Mass and energy balances
  • Functional safety to IEC 61508 and IEC 61511
  • PLC, DCS, SCADA and MMI programming and configuration

How we think and work

Mineralogy. Metallurgy. Chemistry. Materials handling. Contaminant management. Environmental management. We have process engineers and specialists in practically every conceivable process design, development and optimisation discipline.

This means we can create handpicked teams of subject matter specialists who understand the technical, regulatory and commercial requirements. The concepts. The complexity. The consequences. The finest detail.

And crucially, this diversity of process design, development and optimisation expertise and thinking means we can look at your multifaceted project holistically, minimising risk and maximising value at every stage, while keeping your strategic and commercial goals front of mind.


Process design and development

Whether it’s an 85 Mtpa copper concentrator at Cobré Panama, a 5tpd polymeric anti-microbial plant in Australia, or a 9.5 Mtpa gold project in Africa, process development is the first and most critical step in commercialising the science for a project. Commercial success can only be achieved if the correct flowsheet is developed to match inputs and outputs.

Our specialist metallurgists, chemical engineers and chemists take the results of testwork and develop a bespoke flowsheet to suit your specific requirements.

Process optimisation

Over time, the inputs to your process and facility can change, with subtle variances resulting in a gradual but steady loss of performance, productivity and profitability. Our process optimisation specialists will work with you to review ongoing performance, identifying opportunities for process optimisation or the introduction of new ideas and technologies that enhance project performance.

At Lycopodium, we spend our working lives developing new ways to maximise recovery, reduce operating costs, conduct de-bottlenecking and improve capital efficiency. All this knowledge and experience is brought to bear during a process optimisation exercise, enabling you to extract maximum value from your operating assets.


Set up your process and project to succeed from day one

Greenfield or brownfield projects. Testwork design and interpretation. Comminution projects. Process selection studies and pilot plant design, construction management and operation. Commissioning, training and operations services. Plant audits, de-bottlenecking evaluations and staged development planning. Environmental compliance processes. Our process development and optimisation expertise spans the liberation, pre-concentration, beneficiation and extraction spectrum.

Moreover, our mineral process teams have designed and developed processes for an array of metals and mineral commodities, from precious and base metals, to battery metals and bulk commodities. Our diverse group is widely acknowledged as market leaders in grinding circuit design and optimisation, gold process design and optimisation, and diamond recovery processes.

Industrial Processes

Minimise process risk. Maximise commercial performance

From pharmaceutical alkaloid products, to Astaxanthin micro-algae production. From fermented milk, to sauce production. From H2S scrubbing, to biodiesel manufacture. Our chemical engineers have been involved in process modelling, process development and mass and energy balances for some unusual and unique processing facilities.

Find out how our process design and development teams incorporate automation through PLC, DCS, SCADA and MMI programming and configuration, while complying functional safety to IEC 61508 and IEC 61511 standards. Discover how our process optimisation engineers can maximise performance by seamlessly incorporating new ideas and technologies into your processes on an ongoing basis.

Want to talk process development and optimisation?
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