Ferrosilicon Blending Strategies to Improve Separation Efficiency
DMS Powders
Ferrosilicon Blending Strategies to Improve Separation Efficiency
Getting More from Dense Media Separation
If you’re responsible for keeping a DMS circuit running, you know that every small tweak can have a major impact on both recovery and running costs. One of the most underrated ways to push separation performance is through clever ferrosilicon blending strategies. It’s not just about buying the right product—it's about how you use and combine those products to deliver a stable medium, reliable cut point, and less waste in your process.
DMS Powders:
Why Blending Ferrosilicon Matters in Real-World Plants
Dense media separation relies on suspending ferrosilicon in water to create a medium dense enough to float lighter waste and sink your pay dirt. The trick is to hold that density steady, shift the cut point if needed, and keep losses low. But ferrosilicon isn’t one-size-fits-all. Different types—think atomised versus milled, coarse versus fine—have distinct characteristics, and blending them smartly can give your DMS circuit a real edge.
Take a coal washery, for example. Operators might start with a pure milled grade for sharp separation but find the medium isn’t as stable as they'd like. By blending in a percentage of atomised ferrosilicon, the suspension stays more stable, and losses to overflow decrease. On the flip side, in a diamond recovery plant, a manager might blend two atomised grades to adjust density or cut point precisely for changing ore feeds. It’s these subtle shifts that often drive real improvements in both recovery rates and operational costs.
How Blending Impacts Medium Stability and Recovery
It’s all about balancing stability, recoverability, and cost. Here’s how different blending strategies come into play:
- Medium Stability: Coarser ferrosilicon (like Coarse Atomised or 65D milled) tends to settle out less, helping the medium stay consistent. Finer grades can help fine-tune the density but may be lost more easily with the process water. Blending lets you find the sweet spot—stable enough to run reliably but not so fine that you’re throwing money away with every batch.
- Density Control: Adjusting the ratio of coarse to fine ferrosilicon allows for precise control over the medium’s density. Need a higher cut point for a particular ore? Tweak the blend to match.
- Reducing Ferrosilicon Loss: Some sites find that introducing a certain percentage of coarser atomised product reduces ferrosilicon losses significantly, compared to running a single grade. Less ferrosilicon lost means fewer trips to the supplier—and less money out the door.
Want to get a deeper technical understanding of how DMS circuits work? You’ll find a straightforward explanation here.
Blending Strategies in Practice
There’s no universal formula—it comes down to your plant, ore, and objectives. But here are a few practical approaches:
Customising the Blend for Feed Variability:
If your feed changes with the seasons or with new mining areas, adjust the blend to match. More fines might be needed for higher-density ores, while a stable, coarse-heavy mix could suit lighter feeds.
Continuous Monitoring and Adjustment:
The best operators don’t “set and forget.” They regularly check medium density, viscosity, and losses, tweaking the blend as needed.
Batch vs. Inline Blending:
Some plants pre-blend batches of ferrosilicon before adding to the circuit, while others dose different grades directly into the sump or tank for instant mixing. The right method depends on your equipment and the level of control you need.
One South African plant, for instance, managed to cut ferrosilicon losses by over 20% just by introducing a controlled blend of fine and coarse atomised grades, rather than relying on a single specification.
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Automised FeSi
Coarse, Fine, Cyclone 60, Cyclone 40, DMS 70
Milled FeSi
65D, 100D, 150D, 270D, 270F
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DMS Powders: Ferrosilicon for Every Blending Need
Not all suppliers offer the kind of consistency and variety needed for true blending flexibility. DMS Powders stands out for producing both atomised and milled ferrosilicon, with a product line that’s designed for custom blending and plant optimisation. If you’re exporting to other markets or running multiple plants, their ability to deliver consistent quality, anywhere in the world, is a major advantage—check out their role as an exporter of ferrosilicon.
Here’s a quick look at their product range, all engineered for DMS blending:
Milled Ferrosilicon:
- 65D
- 100D
- 150D
- 270D
- 270F
Perfect for coal and general mineral separation, milled grades are prized for their ability to create a reliable medium and keep losses under control.
Atomised Ferrosilicon:
- Coarse
- Fine
- Cyclone 60
- Cyclone 40
- DMS 70
Atomised products are ideal for diamond recovery and high-value ore processing, where precision and stability are non-negotiable. The variety means you can dial in exactly the blend your circuit needs.
For the full product breakdown and technical specs, take a look at the DMS Powders product page.
DMS Powders: Ferrosilicon for Every Blending Need
Not all suppliers offer the kind of consistency and variety needed for true blending flexibility. DMS Powders stands out for producing both atomised and milled ferrosilicon, with a product line that’s designed for custom blending and plant optimisation. If you’re exporting to other markets or running multiple plants, their ability to deliver consistent quality, anywhere in the world, is a major advantage—check out their role as an exporter of ferrosilicon.
Here’s a quick look at their product range, all engineered for DMS blending:
Milled Ferrosilicon:
- 65D
- 100D
- 150D
- 270D
- 270F
Perfect for coal and general mineral separation, milled grades are prized for their ability to create a reliable medium and keep losses under control.
Atomised Ferrosilicon:
- Coarse
- Fine
- Cyclone 60
- Cyclone 40
- DMS 70
Atomised products are ideal for diamond recovery and high-value ore processing, where precision and stability are non-negotiable. The variety means you can dial in exactly the blend your circuit needs.
For the full product breakdown and technical specs, take a look at the DMS Powders product page.
Getting the Most from Your DMS Process
If your goal is to run a tight ship—less ferrosilicon lost, more valuable ore recovered, and fewer process upsets—fine-tuning your blending strategy is a great place to start. Partnering with a supplier that knows DMS inside out, like DMS Powders, takes the guesswork out of the equation. With the right combination of products, advice, and after-sales support, your plant can consistently hit its targets without unnecessary headaches.
If you’re after tailored advice or want to discuss custom blends for your operation, get in touch with DMS Powders for solutions that work in the real world, not just on paper. With a bit of smart blending, the results often speak for themselves.
We supply to:
Ferrosilicon Supplier in Greece | Ferrosilicon Suppliers in South Africa | Ferrosilicon Supplier in Spain | Ferrosilicon Supplier in Brazil | Ferrosilicon Suppliers in Africa | Ferrosilicon Suppliers in China | Ferrosilicon Supplier in Peru | Ferrosilicon Supplier in Russia | Ferrosilicon Supplier in Canada | Ferrosilicon Suppliers in Botswana | Ferrosilicon Suppliers in Namibia | Ferrosilicon suppliers in Angola | Ferrosilicon Suppliers in Zimbabwe | Ferrosilicon Suppliers in Ghana | Ferrosilicon Suppliers in Lesotho | Ferrosilicon Suppliers in Guinea | Ferrosilicon Supplier in DRC | Ferrosilicon Supplier in Sierra Leone | Ferrosilicon Suplier in Tanzania | Ferrosilicon Supplier in Nigeria | Ferrosilicon Supplier in Central African Republic | Ferrosilicone Supplier in Ivory Coast | Ferrosilicone Supplier in Mali