Mining operations are inherently complex, capital-intensive, and risk-sensitive. Alfred H Knight (AHK) is supporting mining operations globally by applying mineral processing expertise to support project development and process optimisation.

James Gaydon, Principal Metallurgist, leads mineral processing consultancy and metallurgical testing programmes that help mining and exploration companies across the project lifecycle, from ore characterisation to generating processing flowsheets. Through close collaboration with clients, James is helping translate laboratory data into processing strategies that support informed decision-making at each stage of a project.

Mineral Processing Expertise: James’ Role in Project Development

Much of James’ work centres on a fundamental question in mining: How do you turn ore into a saleable concentrate?

“A client will often understand the size of their ore body and its mineralogy,” James explains. “What they need to understand then is how to process it — how to separate minerals from gange (waste), and produce a concentrate.”

James and his team support clients in designing practical processing solutions by evaluating ore hardness, assessing separation techniques such as flotation, to, develop metallurgical flowsheets that reflect how the material behaves in practice, not just in theory. This is mineral processing in action.

A Day in the Life of a Principal Metallurgist

No two days, and no two ores, are the same.

“Even if you take two copper ores,” James explains, “they may appear similar mineralogically, but subtle differences in composition can mean they require completely different processing approaches.”

This variability defines much of James’ work. Each project demands technical agility, structured investigation, and close collaboration with both colleagues and clients.

“We often have a clear initial direction,” he says, “but it doesn’t always go exactly to plan. That’s where flexible thinking becomes essential, working closely with the client to develop pragmatic, workable solutions based on real results.”

Custom Solutions, Not Standard Templates

While James and his team operate in line with recognised industry standards, their approach goes beyond applying fixed test programmes.

“We don’t simply run a predefined list of tests and stop there,” he explains. “We interpret results as we go. If something doesn’t behave as expected, we pause, discuss it with the client, and adapt the programme accordingly.”

This consultative approach means AHK works closely with clients, developing processing strategies that reflect specific material behaviour, whilst considering project objectives and operational constraints. The outcome is robust, data-driven insight tailored to each project.

Life at AHK: Purpose, People, and Possibility

For James, working at Alfred H Knight is defined by the people, the values, and the variety of work.

“The people are a huge part of it,” he says. “We have a dedicated team, all working towards the same objective. Seeing different disciplines come together to deliver a solution is incredibly rewarding.”

He also points to the breadth of work as a key motivator: “Different commodities, different ores, different clients, different requirements, it keeps everything dynamic. It keeps the work interesting.”

“The most satisfying part of the job is seeing a solution we’ve developed move beyond the test work and into design or implementation.”

Independent Support from Mineral Processing Experts

Mineral processing is a key step in mining and commodity production. Alfred H Knight provides independent, end-to-end technical support, from exploration and feasibility studies to plant design, ore processing, and trade.

Our services help clients:

• Optimise plant performance
• Refine extraction processes
• Improve operational efficiency

Through metallurgical testing, mineralogical analysis, and consultancy, we turn complex ore behaviour into practical, actionable insights.

Contact Alfred H Knight to speak with one of our mineral processing specialists.