Dense Media Separation

Overview

Consulmet is a world leader in Dense Media Separation (DMS) technology.  We developed our first DMS modules in 2006 and now have dozens operating in mines worldwide for major producers, including Rio Tinto, Anglo American, Gécamines, and Gem Diamonds. 

We offer a full bespoke DMS design service alongside our extensive range of pre-engineered DMS modules and plants.   Our in-house DMS Test Plant is available for pilot testwork and the production of bulk concentrate samples for offtake agreements.

Consulmet has designed, built and operated coarse/lump, fine and ultra-fine, and super-high-density DMS modules and multi-stage DMS plants to process:

What is Dense Media Separation?

Dense Media Separation (DMS), also known as Heavy Media Separation, is a technique used to separate particles based on their density.  DMS is commonly used to pre-concentrate lithium ores, iron ore, and diamonds and to "wash" coals.

The primary principle of DMS involves introducing the feed material into a medium with a density different to the target material and the unwanted waste material.  The particles in the feed material will float or sink in the medium, allowing for easy separation.

A basic step-by-step description of the process is as follows:

1. The feed is prepared to a specific size range.  This is important because the separation in DMS is size sensitive.

2. The prepared feed is mixed with the dense medium (a mixture of powdered ferrosilicon or magnetite in water to create a fluid with a specific density).

3. The mixture is introduced into a cyclone, where a controlled vortex is formed.  Due to the density difference under gravity, lighter particles move to the centre and are transported upward through the vortex.  Denser particles move to the outer edge and are transported downwards.

4. The separated valuable minerals and waste materials are collected separately for further treatment or disposal.

5. After separation, the dense medium is recovered using screens and magnetic separators, and then it is cleaned and reused.

DMS is a powerful and efficient technique due to its high capacity, ability to treat a wide range of particle sizes (from 75 mm down to less than 0.5 mm), and high efficiency in separating different minerals based on density.  However, the process requires precise control to ensure that the density of the medium and the feed material are correctly matched.

Our DMS Design Philosophy

Our DMS plants are designed to the Dutch State Mines' principles and incorporate the latest innovations in DMS design, resulting in improved recovery efficiencies, optimised ferrosilicon/magnetite recovery, and ease of operation and maintenance. 

We have developed considerable expertise in all aspects of DMS design and operation, including:

• material feed preparation for fine and ultra-fine DMS circuits;

• the design of high- and ultra-high-density DMS plants; and

• the design of duty and standby pumping circuits for ferrosilicon to avoid ferrosilicon setting in lines.

Our DMS Capability

• Testwork design and management

• Pilot testwork and bulk sampling

• Flowsheet design and modelling

• DMS cyclone simulation

• Ferrosilicon and magnetite selection

• Feed preparation

• Screen selection and sizing

• Mica removal

• Wear lining selection

• Commissioning

• DMS Plant operations.