Ferrosilicon 65D, 100D, and 150D: Buyer’s Guide
DMS Powders
Ferrosilicon 65D, 100D, and 150D: Buyer’s Guide
Let DMS Powders help you to select the right Ferrosilicon Grade for your Dense Media Separation processes.
Choosing the Right Ferrosilicon Grade
When it comes to dense media separation (DMS), the type of ferrosilicon you select can make or break your operation’s efficiency. The choice between Ferrosilicon 65D, 100D, and 150D isn’t only about particle size - it’s about finding the right balance between recovery, stability, and cost-effectiveness for your mineral processing plant.
At DMS Powders, we’ve specialised in producing high-quality atomised and milled ferrosilicon for decades. With strict control over corrosion resistance, abrasion resistance, magnetic recovery, and specific gravity, our products are engineered to keep separation processes stable and economical.
This buyer’s guide breaks down what you need to know about 65D, 100D, and 150D ferrosilicon grades, how they’re used in modern DMS plants, and what to consider before making a purchase.
Technology:
What Makes DMS Powders Ferrosilicon Different?
Consistency in Production
Our ferrosilicon powders are manufactured through a controlled milling process. Each grade - whether 65D, 100D, or 150D - undergoes rigorous testing to ensure consistency in particle size distribution. This consistency directly impacts the density of the medium and the accuracy of separation.
Properties That Matter in DMS
- Corrosion Resistance: Extends the life of the powder even in challenging conditions.
- Abrasion Resistance: Reduces losses from wear and tear inside the separation plant.
- Magnetic Properties: Allow for fast recovery using standard magnetic separators, cutting operational losses.
- High Specific Gravity: Ensures the dense medium remains stable, even with high throughput.
- Economical Operation: Lower losses and higher recovery rates translate into reduced cost per tonne.
Packaging for Real-World Conditions
Every batch of DMS Powders ferrosilicon is packaged to handle the demands of the mining environment. With water-resistant and durable bags, we protect product integrity from the factory floor to your separation circuit.
DMS Powders
What We Stand For
- Profitably maintain our core business through excellence in production, distribution and marketing.
- Develop and enhance global alliances and external relationships to secure optimal market knowledge and increase strategic and operational flexibility.
- Empower employees with knowledge and resources to act in accordance with core values.
- Create industry benefit by providing opportunities for shared technical knowledge and skills.
- Actively manage and build our portfolio of high-quality assets and services.
- Continue the drive towards a high-performance organisation, in which every individual accepts responsibility and is rewarded for results.
- Earn the trust of employees, customers, suppliers, communities and shareholders by being forthright in our communications and consistently delivering on commitments.
- Ethics: Uncompromising honesty, integrity, trust and reliability in our dealings with each other.
- Excellence: Setting high standards in every aspect of business and continuously striving to outperform them.
- Prosperity: Pursuance of productivity and effectiveness to create a fair value proposition for shareholders, customers, employees and suppliers.
- Sustainability: An overriding commitment to safety, environmental responsibility and sustainable development.
Automised FeSi
Coarse, Fine, Cyclone 60, Cyclone 40, DMS 70
Milled FeSi
65D, 100D, 150D, 270D, 270F
DMS Powders
Packaging
Our packaging has been specifically designed for:
Ease of handling
Safety
Product integrity
Durability
Water resistance
Breaking Down the Grades: 65D, 100D, and 150D
Each grade of milled ferrosilicon serves a unique purpose within dense media separation. Let’s look closer at the practical applications of the three grades most commonly used.
Ferrosilicon 65D
65D is known for its coarser particle size compared to finer grades. It’s often chosen for operations where:
- A more robust medium is needed for handling large or abrasive mineral feeds.
- Stability is more important than precision cut density.
- Recovery systems can easily handle the slightly heavier magnetic particles.
Ferrosilicon 100D
100D is considered the all-rounder of ferrosilicon grades. It offers a balance between stability and recovery efficiency. Many diamond and mineral processing plants rely on 100D as their go-to grade because it:
- Provides stable suspensions for medium- to fine-sized ore particles.
- Achieves accurate cut densities with minimal slimes interference.
- Is easier to recover magnetically than finer grades.
Ferrosilicon 150D
150D falls into the finer milled ferrosilicon category. It is used when precision separation is critical, especially in plants that demand very sharp cut densities. Its finer particles mean:
- Excellent suspension stability even at lower concentrations.
- Higher surface area, which requires careful recovery handling.
- Ideal for separating smaller or more delicate mineral fractions.
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Frequently Asked Questions about Ferrosilicon
Factors to Consider When Selecting a Grade
Type of Ore or Mineral
The size, shape, and density of your feed material will often dictate whether you should lean towards 65D, 100D, or 150D. Larger and tougher ore feeds tend to work better with 65D, while more delicate minerals benefit from 150D.
Recovery Systems
Your plant’s magnetic separation technology must align with the grade you choose. Finer powders like 150D require highly efficient recovery circuits to avoid unnecessary loss.
Cost vs Performance
Coarser ferrosilicon powders like 65D may be more economical on recovery but offer less precision. On the other hand, 150D can provide extremely accurate separation at the cost of slightly higher recovery challenges. Many operations find 100D the ideal middle ground.
Benefits of Using Milled Ferrosilicon from DMS Powders
Improved Plant Efficiency
With reliable ferrosilicon grades, you can maintain sharper separations, which means less misplaced material and more efficient downstream processes.
Lower Operating Costs
Magnetic recovery systems paired with durable ferrosilicon reduce replacement frequency, lowering your total operating expenditure.
Product Integrity You Can Rely On
From the packaging design to the uniform milling process, every aspect of DMS Powders’ ferrosilicon is engineered to perform consistently under harsh plant conditions.
Packaging and Handling
We supply ferrosilicon in packaging designed for practicality in the field. The bags are:
- Water-resistant to protect product quality.
- Durable enough for rough handling during transport.
- Easy to move and stack in bulk storage facilities.
Packaging is available in different sizes, ensuring you only handle as much product as your process requires.
Frequently Asked Questions
What’s the main difference between Ferrosilicon 65D, 100D, and 150D?
It comes down to particle size. 65D is coarser, 100D is balanced, and 150D is finer. Your choice should match the precision of separation needed and the ore being processed.
Can different grades be blended?
In some plants, blending two grades creates a customised suspension. For example, mixing 100D and 150D may offer both stability and precision. However, this should only be done with expert advice to avoid compromising recovery.
How does ferrosilicon compare with other DMS media?
Alternatives such as magnetite are available, but ferrosilicon generally provides higher density and better recovery properties, which is why it’s preferred in diamond, mineral, and metals separation.
What’s the lifespan of ferrosilicon in DMS plants?
Lifespan depends on handling, ore type, and recovery efficiency. Thanks to its corrosion and abrasion resistance, DMS Powders ferrosilicon lasts longer and reduces replacement costs.
Partner with DMS Powders
Supplier of Atomised & Milled Ferrosilicon Powder
Ferrosilicon 65D, 100D, and 150D each have their place in dense media separation. The right grade for your operation depends on your ore type, plant configuration, and recovery requirements. At DMS Powders, we’ve seen first-hand how the correct choice can improve plant yield, lower operating costs, and create consistent results.
If you’re uncertain about which grade best suits your plant, our technical team can provide tailored advice based on years of experience supplying ferrosilicon to the global mining industry.
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