Question 1

What is METSIM® and why is it used in mineral processing?

Accepted Answer

METSIM® is a general-purpose process simulation system used to perform mass and energy balances for mineral processing plants. It handles steady-state and dynamic simulation across comminution, flotation, leaching, hydrometallurgy, pyrometallurgy, tailings management, and more.

It is the industry standard for detailed plant modelling because it is built on APL - a programming language that gives engineers unlimited flexibility to model any process.

Over 620 companies across 54 countries use METSIM®. SKEmet works exclusively with METSIM®, delivering deep specialisation rather than spreading expertise across multiple tools.

SKEmet works exclusively with METSIM®, delivering deep specialisation rather than spreading expertise across multiple tools.

Question 2

What is the difference between steady-state and dynamic simulation?

Accepted Answer

Steady-state simulation models your plant at a fixed point in time, a snapshot of normal operating conditions. It is fast to build and ideal for plant design, equipment sizing, and CAPEX estimation.

Dynamic simulation models how the plant behaves over time, accounting for changing feed grades, reagent dosing, water balance shifts, and equipment availability.

Dynamic models are used for life-of-mine planning, heap leach forecasting, digital twins, and operator training.

Question 3

What data do I need to provide before starting a METSIM® simulation?

Accepted Answer

The minimum data depends on your project stage.

For scoping or pre-feasibility: ore characterisation data, a process flow diagram, and target throughput and recovery figures.

For feasibility or detailed design: metallurgical testwork results, equipment specifications, reagent dosing data, and water balance inputs.

SKEmet will assess what you have during the initial scoping conversation and identify any gaps - we routinely work with incomplete datasets.

Question 4

How long does it take to build a METSIM® plant model?

Accepted Answer

Timeline depends on plant complexity, data availability, and scope.

A focused steady-state mass balance for a single circuit can be completed in a matter of weeks.

A full plant model covering comminution, flotation, leaching, and tailings management may take two to four months.

SKEmet provides a specific timeline estimate after the initial scoping conversation, once we understand your deliverables and deadlines.

Question 5

Do I need to run a pilot plant before commissioning a simulation?

Accepted Answer

No. METSIM simulation can be built from laboratory testwork and metallurgical data alone, a full pilot plant is not required.

Simulation is often a more cost-effective first step, letting you compare multiple process configurations digitally before committing capital to physical infrastructure.

Where pilot plant data does exist, it strengthens model calibration and increases confidence in predictions.

Question 6

What is a process digital twin and how is it different from a simulation model?

Accepted Answer

A simulation model is a one-time or periodically updated representation of your plant.

A digital twin is a living model, continuously updated with real plant data so it mirrors actual operating conditions in near real time.

Digital twins allow engineers to test process changes, forecast production, and make operational decisions without disrupting the physical plant.

SKEmet builds the METSIM dynamic simulation foundation that underpins a digital twin.

Frequently asked questions