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Carrousel Rail
Multizone C Configuration
mt DMS Plant Configurations
Mineral Technologies offers modular Dense Media Separation plants across a wide range of capacities and applications. Each plant is designed around the mineral DNA of the orebody, ensuring stable separation performance under real operating conditions.
Two representative examples of our modular plant families are shown below. The mt DMS C-Series focuses on compact and flexible installations, while the mt DMS M-Series is designed for larger throughputs and more demanding processing environments.
mt DMS C-Series vs mt DMS M-Series
| Parameter | C65 | M150 | M180 |
|---|---|---|---|
| Typical Throughput | Up to 65 t/h | From 150 t/h | From 180 t/h |
| Plant Type | Compact modular DMS plan | tLarge modular DMS plant | Large modular DMS plant |
| Typical Application | Smaller operations, modular expansions, pilot plants | Large-scale operations and high-capacity pre-concentration | Large-scale operations and high-capacity pre-concentration |
| Cyclone Configuration | 1 × 510 mm cyclone | 2 × 510 mm cyclones | 2 × 610 mm cyclones |
| Extra information | Smaller operations, modular expansions, pilot plants | Large-scale operations and high-capacity pre-concentration | Large-scale operations and high-capacity pre-concentration |
| Extra information 2 | 1 × 510 mm cyclone | 2 × 510 mm cyclones | 2 × 610 mm cyclones |
| Third extra bonus information | Smaller operations, modular expansions,, modular expansions,, modular expansions, pilot plants | Large-scale operations and high-capacity operations and high-capacity operations and high-capacity pre-concentration | Large-scale operations and high-capacity operations and high-capacity operations and high-capacity pre-concentration |
Full capacity range
mt DMS plants cover capacities from approximately 10 tonnes per hour to 4,000 tonnes per hour, each engineered around the orebody, separation target and operating context of the mine.
Multizone D Configuration
mt DMS Plant Configurations
Mineral Technologies offers modular Dense Media Separation plants across a wide range of capacities and applications. Each plant is designed around the mineral DNA of the orebody, ensuring stable separation performance under real operating conditions.
Two representative examples of our modular plant families are shown below. The mt DMS C-Series focuses on compact and flexible installations, while the mt DMS M-Series is designed for larger throughputs and more demanding processing environments.
Simple physics. Demanding execution.
Dense Media Separation uses a simple principle: particles with different densities behave differently in a dense liquid.
By mixing crushed ore with a slurry containing ferrosilicon (FeSi), operators create a medium with a carefully controlled density. Particles lighter than the medium float, while heavier particles sink.
This allows valuable minerals to be separated from waste based purely on apparent density.
DMS operates most effectively within a defined particle size range. In typical applications, material between approximately 0.5 mm and 50 mm is treated, with some applications extending up to 100 mm depending on the ore characteristics and plant design.
This makes DMS fundamentally different from fine particle processes such as flotation, which operate on much smaller particle sizes. Instead, DMS targets the coarse fraction of the ore — where large volumes of waste can be rejected early in the process.
Gravity separation vs density separation
In conventional gravity separation, particles settle slowly according to their natural density differences. In Dense Media Separation, the process is accelerated and controlled by suspending particles in a dense medium that immediately forces the separation.
Inside a DMS cyclone, the slurry is exposed to strong centrifugal forces that further intensify the separation. Heavier particles move outward and report to the sink product, while lighter material exits through the float stream.
The medium is then recovered through drain, rinse and magnetic circuits before being returned to the process.
Where experience matters
While the principle is straightforward, maintaining stable separation conditions is where expertise becomes critical.
Separation efficiency depends on:
- consistent medium density
- well-prepared feed material
- stable cyclone pressure and flow conditions
- efficient recovery of the ferrosilicon medium
Small deviations like excess fines, unstable pressure or medium losses can quickly reduce recovery and increase operating costs.
That is why mt DMS plants are engineered not only for separation itself, but for maintaining stable process conditions throughout the entire circuit.
Where experience shapes performance
In a DMS plant, the equipment itself is well understood. Screens, pumps, cyclones and magnets all have known specifications and behaviour. The difference lies in how these elements are integrated and tuned to match the characteristics of the orebody.
At Mineral Technologies, plant design begins with understanding the mineral DNA of the deposit. Test work determines the density behaviour of the ore and defines the optimal separation window. From there, the plant is configured to maintain those conditions consistently in real operation—even as parts wear and operating conditions evolve over time.
- Feed preparation Proper screening protects the medium from excessive slimes and ensures particles enter the cyclone in the correct size range for efficient separation.
- Medium conditioning and mixing Carefully designed mixing boxes maintain consistent density and prevent issues such as rafting or uneven distribution.
- Cyclone control Stable feed pressure and correct medium density ensure reliable separation efficiency and predictable product quality.
- Medium recovery circuit Drain and rinse screens plus magnetic recovery return ferrosilicon to the process and help keep operating costs under control.
- Designed for real operating conditions Pumps, which experience significant wear in dense medium circuits, are positioned for quick access and replacement, ensuring the plant maintains performance and availability with minimal downtime.
Gravity Separation vs. Density Separation
In conventional gravity separation, particles settle slowly according to their natural density differences. In Dense Media Separation, the process is accelerated and controlled by suspending particles in a dense medium that immediately forces the separation.
Inside a DMS cyclone, the slurry is exposed to strong centrifugal forces that further intensify the separation. Heavier particles move outward and report to the sink product, while lighter material exits through the float stream.
The medium is then recovered through drain, rinse and magnetic circuits before being returned to the process.
Where experience matters
While the principle is straightforward, maintaining stable separation conditions is where expertise becomes critical. Separation efficiency depends on:
- consistent medium density
- well-prepared feed material
- stable cyclone pressure and flow conditions
- efficient recovery of the ferrosilicon medium
Small deviations like excess fines, unstable pressure or medium losses can quickly reduce recovery and increase operating costs. That is why mtDMS plants are engineered not only for separation itself, but for maintaining stable process conditions throughout the entire circuit.
Feed preparation
Proper screening protects the medium from excessive slimes and ensures particles enter the cyclone in the correct size range for efficient separation.
Medium conditioning and mixing
Carefully designed mixing boxes maintain consistent density and prevent issues such as rafting or uneven distribution.
Cyclone control
Stable feed pressure and correct medium density ensure reliable separation efficiency and predictable product quality.
Medium recovery circuit
Drain and rinse screens plus magnetic recovery return ferrosilicon to the process and help keep operating costs under control.
Designed for real operating conditions
Pumps, which experience significant wear in dense medium circuits, are positioned for quick access and replacement.
Minimal Downtimes
Ensuring the plant maintains performance and availability with minimal downtime.
Benefits
Higher Mineral Recovery
Stable medium density and optimised cyclone conditions recover valuable minerals from coarse fractions often lost in conventional circuits.
Controlled FeSi Consumption
Efficient magnetic recovery and well-managed medium circuits minimise ferrosilicon losses and stabilise operating costs. Learn more about FeSi selection →
Separation You Can Trust
Designing the circuit around your mineral DNA ensures stable and predictable separation.
Real-World Reliability
Plants are engineered to compensate for feed variability, wear and operational fluctuations.
Easy Maintenance Access
Accessible layouts simplify equipment replacement and routine maintenance for high plant availability.
Modular Plant Design
Blockframe® modules allow fast installation, easy transport and scalable capacity as operations grow.
Designed for Your Ore
Targeted test work translates density behaviour into a plant configuration tailored to your deposit.
Operational Simplicity
mtDMS process control and automation support efficient operation with lean plant crews.
Smarter Medium Management
Our fine mineral processing expertise optimises medium recovery, protecting performance and OPEX.
Ready for mtOne
Digital monitoring enables remote insights, faster troubleshooting and future plant optimisation.
mtDMS for Tin
- Recover valuable cassiterite from coarse fractions before grinding
- Concentrate feed prior to gravity circuits such as shaking tables
- Reject waste early and increase effective plant throughput
- Improve project economics by upgrading head feed
mtDMS for Iron Ore
- Reject low-density gangue before grinding and beneficiation
- Increase plant throughput by reducing downstream processing loads
- Stabilise feed grade for downstream processing circuits
- Improve overall resource utilisation
mtDMS for Coal
- Separate coal from rock using density-based separation
- Achieve high recovery with low product dilution
- Produce consistent product quality across variable feed conditions
- Proven technology in high-availability coal preparation plants
mtDMS for Lithium
- Concentrate spodumene before energy-intensive flotation circuits
- Reject barren gangue early in the flowsheet
- Reduce grinding and flotation loads
- Improve project economics for hard rock lithium operations
mtDMS Plant Configurations
Mineral Technologies offers modular Dense Media Separation plants across a wide range of capacities and applications. Each plant is designed around the mineral DNA of the orebody, ensuring stable separation performance under real operating conditions.
Two representative examples of our modular plant families are shown below. The mtDMS C-Series focuses on compact and flexible installations, while the mtDMS M-Series is designed for larger throughputs and more demanding processing environments.
| Parameter | mtDMS C-Series (Example: C65) | mtDMS M-Series (Example: M150) |
|---|---|---|
| Typical Throughput | Up to 65 t/h | From 150 t/h |
| Plant Type | Compact modular DMS plant | Large modular DMS plant |
| Typical Application | Smaller operations, modular expansions, pilot plants | Large-scale operations and high-capacity pre-concentration |
| Cyclone Configuration | 1 × 510 mm cyclone | 2 × 510 mm cyclones |
| Top Feed Size | ~25 mm | ~32 mm |
| Yield to Product | Up to ~80% (ore dependent) | Up to ~80% (ore dependent) |
| Ore : Medium Ratio | Typically 3:1 – 7:1 | Typically 3:1 – 7:1 |
| Footprint | ~20 m × 10 m × 8 m | ~24 m × 12 m × 13 m |
| Transport | Containerised modules (3 × 12m containers) | Containerised modules (10 × 12m containers) |
Matthew Allen
General Manager – Business Development
Making a real difference to a project and enriching / improving the lives of others in some way. Enjoying the company of other like-minded people who work in our fantastic little company.
Reach Out!
Ready to explore how our processing solutions can maximise your iron ore project? We’re here to help. Reach out to us today to learn more about how we can tailor our solutions to meet your specific needs and objectives.
Get in touchFrequently Asked Questions about mtDMS plants
What is Dense Media Separation?
Dense Media Separation (DMS) is a process used to separate minerals based on their density. Crushed ore is mixed with a dense slurry, typically made from water and ferrosilicon, allowing heavier minerals to sink while lighter material floats. This enables early rejection of waste and recovery of valuable minerals before energy-intensive downstream processing.
What is the medium in Dense Media Separation?
The medium is the dense slurry used to perform the separation. In most DMS plants this slurry consists of water mixed with finely ground ferrosilicon. Maintaining the correct density and cleanliness of the medium is essential for reliable separation performance.
What does the cut point mean in DMS?
The cut point is the density at which particles are separated into sink and float products. Particles denser than the cut point report to the sink stream, while lighter particles report to the float stream. Determining and maintaining the correct cut point is a key outcome of the test work and plant design process in mt DMS plants.
Is DMS suitable for all particle sizes?
DMS works best within a defined particle size window where density differences can be effectively exploited. Typical applications treat coarse material before grinding, often in the millimetre size range. Our specialists determine the optimal size fractions during test work and design the feed preparation accordingly.
How does mt ensure stable separation performance?
Stable separation depends on consistent medium density, correct feed preparation, and reliable cyclone operation. Our mt DMS plants are designed to maintain these conditions through carefully integrated screening, mixing, pumping and cyclone circuits, ensuring the plant performs reliably even when feed conditions vary.
How important is test work for a DMS project?
Test work is critical because every orebody behaves differently in dense media separation. Our team analyses the density characteristics of the deposit to determine the optimal separation density, particle size range and flowsheet configuration. This ensures the final plant design matches the mineral DNA of the ore.
What is circulating medium (CM)?
Circulating medium refers to the dense slurry that continuously flows through the DMS separation circuit. In mt DMS plants this medium is carefully controlled to maintain consistent density and stable separation conditions in the cyclone.
What is dilute medium (DM)?
Dilute medium is the slurry after it has been mixed with rinse water or process streams, reducing its density compared to the circulating medium. Efficient recovery circuits restore the correct density before the medium is returned to the process.
What does cyclone differential mean in DMS?
Cyclone differential refers to the pressure difference across the cyclone, which strongly influences separation performance. Maintaining stable differential pressure is important for consistent operation, and mt DMS circuits are designed to support stable cyclone conditions.
How reliable are DMS plants in operation?
Dense Media Separation is a mature and robust technology used worldwide. Our mt DMS plants are engineered for real operating conditions, with accessible equipment layouts and proven circuit designs that support high plant availability and straightforward maintenance.
Why is feed preparation critical for DMS performance?
Efficient separation depends on properly prepared feed material. Removing fines and slimes through pre-washing and screening helps maintain medium stability and improves separation efficiency inside the cyclone.
How do fines and slimes affect DMS performance?
Excess fines and slimes can contaminate the dense medium and increase viscosity, which reduces separation efficiency. Effective scrubbing and screening help remove these particles before the material enters the DMS circuit.
Why is good housekeeping important in a DMS plant?
Build-up of ferrosilicon, ore, or slurry around structures and equipment can lead to medium losses, contamination and operational inefficiencies. Good housekeeping helps maintain stable plant conditions and ensures safe and easy access for maintenance.