Since 1986, BRGM has been developing a powerful software package, USIM PAC. It is an easy to use steady-state simulator which makes it possible for the mineral processing specialist to profit from available experimental data to model plant operations, and then find an optimal plant configuration to meet required objectives. Designers of new plants can also work with this simulator to calculate the sizes and settings required to achieve a given circuit objective. This software package includes functions to manage experimental data, to calculate coherent material balances, sizes and settings of units of equipment, physical properties of the processed material, to simulate plant operations and display results on tables and graphics. Widely used to design and optimize industrial plants, with more than one hundred copies in twenty-six countries, this software has been improved, through successive versions, to make it more accurate and easier to use. Developed in the MS-DOS environment, the evolution was limited because of calculation time and memory management capacity. To overcome these difficulties, the Process Simulation Group has chosen a new environment, Windows 3, which allows powerful calculation possibilities, associated at a very friendly interface, making the software really intuitive for the mineral processing engineer. Since the first version, numerous mathematical models for unit operations have been included and today most of the physical treatments of mineral processing can be reproduced by the simulator: crushing, screening, grinding, flotation, gravity and magnetic separation, solid-liquid separation, etc. The new USIM PAC 2, contains all the functions of the previous version but also new algorithms such as a material balance calculation, the Objective Driven Simulation and the Supervisor of Simulation. Its structure is now open to new fields of activity such as hydrometallurgy, fine grinding, soil decontamination or mining waste treatment. New models have already been included for some of these fields. The improvements of the simulator will be presented and some applications of the new capabilities on complex ores in Portugal, India and France will be briefly described.