The observed behaviours of mineral particles in mineral processing operations have been exploited in the past to model comminution and concentration processes. In this work this concept has been taken a step further, exploiting the mineralogical characteristics of particles to link comminution, concentration and smelting. This approach is demonstrated using a laboratory-based case study of a Ni-Cu sulphide ore. The case study focused on the effect of shifting energy between the comminution and smelting stages on the overall energy consumption for the metal production process. To model this effect the mineral composition of the particles was linked to the behaviour of the ore particles in the primary grinding, regrinding and flotation stages. This application of process mineralogy provides a methodology to minimise energy use across mineral concentration and smelting processes, an important aspect of sustainable processing. (C) 2011 Elsevier Ltd. All rights reserved.