Numerous bulk solid processing plants have been experiencing flow problems during handling, storage and transportation. In the present work, the concept of using superabsorbent polymers (SAP) to improve the flow of bulk solids particularly iron ore was investigated. Physical properties, absorption properties and mechanical properties of different SAPs were determined. Flowability analysis was studied to understand the flow behaviours of iron ore at various moisture levels ranging from 4% to 12%. Flow function curves for 12% moisture iron ore showed the change of flow regime from cohesive to easy-flow in the presence of SAP. The dosage of 100 g/ton and retention time of 30 min were obtained and incorporated during plant trials. The iron ore processing plant has achieved an increase in production during trials and 24% increase for long run of SAP during monsoon. (C) 2020 Elsevier B.V. All rights reserved.