An advanced technique for modelling hydrocyclone separation performance has been developed. This technique is based on the combined modelling of hydrocycloning parameters and virtual' iron ore feed._x000D_
The virtual feed modelling was performed using a novel (in-house) software package called Recognition', which uses data from optical image analysis to classify the particles in certain size fractions according to total iron content and calculates data for every grade class. These data include the average mineral composition and density of every liberation class in every size fraction. This information about every size fraction, representing the virtual feed', was input to the mineral processing modelling package USIM PAC. The hydrocycloning process was then modelled for this virtual feed using the Plitt hydrocyclone model. Empirical calibration coefficients for the hydrocyclone model were calculated using an optimisation procedure in Excel._x000D_
Pilot-scale hydrocyclone beneficiation experiments were performed on an iron ore blend, using different hydrocyclone pressures and per cent solids in the feed pulp. These experiments were modelled and the modelling results were compared with the experimental results._x000D_
The new modelling approach enables prediction of the recovery of each mineral in the products, calculation of the total iron grade and recovery, and optimisation of iron ore beneficiation using hydrocyclones.