Using METSIM for Process Simulations: A Practical Guide

In an industry where every percentage of efficiency matters, METSIM has become the go-to simulation tool for process engineers looking to model, optimise, and troubleshoot complex mining systems.

But here’s the problem: Most operations only use a fraction of what METSIM can do. They treat it like a calculator when it should be used like a strategic compass—guiding decisions that lead to real performance gains and cost savings.

If you want to squeeze more value from your plant and stop relying on trial and error, this guide will help you unlock METSIM’s full potential.

1. What METSIM Really Does (When Used Properly)

METSIM isn’t just for generating pretty flow diagrams—it’s a full-suite simulation engine that lets engineers design, test, and refine process systems digitally.

Here are the most impactful features when used effectively:

Mass and Energy Balances – Model and balance inputs/outputs across the entire plant to detect losses and inefficiencies.
Flotation Circuit Simulation – Optimise recovery by adjusting variables like reagent dosage, air flow, and residence time.
Grinding & Comminution Modelling – Evaluate the energy demand and performance of mills to reduce power consumption and improve liberation.

When you simulate before you implement, you save money before it’s even spent.

2. Common Mistakes That Undermine Simulation Accuracy

Even the best simulation software can produce bad results if it’s fed bad data—or used with flawed assumptions. These are the top mistakes we see in the field:

Incorrect Inputs – Feed grades, flow rates, and temperatures are often estimated or outdated. The model reflects your guess, not your plant.

No Real-Time Feedback – Without integrating sensor data, models can’t reflect live process conditions, making your simulations reactive instead of predictive.

Surface-Level Use – Many engineers only use METSIM for static balances, ignoring its potential for forecasting, process control testing, and debottlenecking.

3. How to Use METSIM for Maximum Efficiency

If you want to turn METSIM into a profit-driving tool instead of a basic calculator, here’s how:

✅ Clean Your Inputs: Collect accurate, up-to-date data from your plant—especially around feed grades, slurry densities, residence times, and circuit efficiencies. Use daily reconciliations to keep inputs dynamic.

✅ Integrate Real-Time Plant Data: Combine METSIM with sensor feeds and historian data to build adaptive models that respond to real conditions.

✅ Use METSIM for Scenario Testing: Test changes digitally before touching physical infrastructure. From adding a flotation cell to adjusting grind size, simulate the impact before you commit capital.

✅ Simulate Energy & Water Use: Use METSIM to model energy and water footprints. This helps uncover areas where you can reduce consumption without affecting throughput—especially valuable for ESG reporting and compliance.

METSIM is not just a simulation platform—it’s a strategic decision-making engine.

When used right, it doesn’t just tell you how your plant works—it tells you how to make it better.

From recovery rate optimisation to energy reduction and predictive maintenance, METSIM empowers engineers to stop guessing and start fine-tuning.

At SKEmet, we help mining operations unlock the full power of METSIM. Whether it’s reducing reagent costs, increasing plant recovery, or building dynamic models, we turn data into action.