Factors affecting electrical comminution performance were investigated through experimental work and numerical simulations. The effects of feed size, under-sieve classification, incremental breakage and energy input level on particle pre-weakening and mineral liberation were tested with six ore samples. Using commercial software, COULOMB 3D, simulation was used to explore the trends between the electrical field distribution/intensity, and the ore particle electrical/mechanical properties. These results were used to interpret the differences in breakage and liberation for various ores. The results showed that the induced electrical field is strongly dependent on the electrical properties of minerals, the grain size, the location of the conductive minerals in rocks, and the particle shape/orientation. Understanding how the machine-related factors and ore-related factors affect the electrical comminution performance will assist in the machine scale up development. (C) 2012 Elsevier Ltd. All rights reserved.