Dense Medium Separation: Efficient Mineral Separation?

You might be looking for effective ways to separate valuable minerals from waste rock. Dense Medium Separation (DMS), also known as heavy medium separation, is a powerful technique in mineral separation. This process uses a fluid of a specific density to separate particles based on their differing densities.

ZONEDING manufactures a range of DMS equipment and can help you understand if this DMS process is the right fit for your operation, whether it’s for coal washing, iron ore beneficiation, or aggregate purification. This guide will explain the essentials of Dense Medium Separation.

Last Updated: March 2025 | Estimated Reading Time: 20 minutes

What You’ll Learn:

• What is DMS & its working principle?
• Core DMS System Equipment & Synergy?
• Best Ores for DMS & Success Cases?
• Choosing Right Dense Medium: How Critical?
• Key DMS Parameters for Efficiency?
• DMS vs. Jigging/Spirals: Pros & Cons?
• Main DMS Plant Costs (CAPEX & OPEX)?
• When is DMS Not Ideal/Needs Combos?
• Testing Material Suitability for DMS?
• Choosing DMS Equipment: Key Points?
• Future DMS Tech & Opportunities?

What is DMS & its working principle?

Dense Medium Separation (DMS) is a mineral separation technique. It separates particles of different densities. It uses a fluid medium. This medium has a density that is between the densities of the materials you want to separate. The basic principle is simple. Particles denser than the medium sink. Particles less dense than the medium float. This allows for an effective split between valuable minerals and gangue (waste rock).

The “dense medium” itself is typically a suspension of fine, heavy particles in water. Common materials used to create this suspension are finely ground ferrosilicon or magnetite powder. You carefully control the concentration of these particles in water. This achieves the precise separation density required for your specific ore. For example, in coal washing, the dense medium is set to a density where clean coal floats and heavier rock sinks. This is a core part of the DMS process.
The effectiveness of Dense Medium Separation hinges on creating a stable, uniformly dense medium. It also depends on efficiently introducing the feed material. And, of course, cleanly separating the float and sink products. This method is widely used because it can achieve sharp separations. It is often very efficient for a range of particle sizes.

Core DMS System Equipment & Synergy?

A complete Dense Medium Separation system, or DMS equipment setup, involves several key components. These components work in synergy to perform the mineral separation. The heart of the DMS process usually involves a separating vessel and a medium recovery circuit.

• Feed Preparation Circuit:
  • This section ensures the ore or material is suitable for DMS. It usually includes Crushing Equipment to reduce size. It also has Vibrating Screens to remove fines (slimes) that can contaminate the medium and reduce separation efficiency. Proper desliming is critical.
• Dense Medium Mixing and Pumping:
  • A mixing tank (Mixer tank) holds the dense medium, typically a slurry of water and ferrosilicon or magnetite powder. The density is continuously monitored and adjusted. Pumps circulate this medium to the separating vessel.
• Separating Vessel: This is where the actual dense medium sorting occurs. Common types include:
  • Dense Medium Cyclones (DMC): These are widely used for finer particles. The feed slurry (ore mixed with dense medium) is pumped tangentially into the cyclone. Centrifugal forces greatly enhance the gravity separation. Lighter particles exit through the overflow (vortex finder). Denser particles exit through the underflow (spigot). The internal geometry and wear of a Dense Medium Cyclone are critical. Even slight wear in the inlet, overflow, or cone can change flow patterns. This can increase misplaced material. Regular inspection of these “hidden wear zones” is vital.
  • Dense Medium Baths/Vessels (e.g., Drum Separators, Wemco Cones): These are used for coarser particles. Material is fed into a pool of dense medium. Floats are skimmed off the surface. Sinks are removed from the bottom.
• Product Draining and Rinsing Screens:
  • Both the float and sink products from the separating vessel pass over drain and rinse screens (Vibrating Screens).
  • First, undiluted dense medium drains off and returns directly to the circuit (densified medium).
  • Then, water sprays rinse the remaining adherent medium from the products. This “dilute medium” goes to the medium recovery circuit. The “art of rinsing” on these screens is crucial. Spray water quality, pressure, and volume must be optimized. Poor rinsing means lost medium with products. It can also mean sending excessive fines to recovery, or even washing fines back into the product.
• Medium Recovery Circuit: This is essential for economic viability, as the medium (e.g., ferrosilicon) is valuable.
  • Magnetic Separators: If using a magnetic medium like ferrosilicon or magnetite powder, wet low-intensity Magnetic Separators (LIMS) are used. These recover the magnetic particles from the dilute medium. The choice and condition of the Magnetic Separator are important. Loss of fine, fresh medium particles can occur if magnetic recovery is not optimal. This leads to “selective wear” and “component drift” in the circulating medium.
  • Densifiers (e.g., Thickeners, Cyclones): The recovered medium is often densified using a Hydrocyclone or a Thickener. This removes excess water before it’s returned to the main DMS circuit.
• Medium Quality Control:
  • Systems monitor and control medium density and viscosity. Contaminants like slimes are removed via a bleed stream or specific cleaning circuits (e.g., wet screening of the medium). The “rheological devil” – where medium viscosity increases due to slimes or degraded medium, even if density looks okay – can kill separation efficiency. This is especially true for near-density material. Regular rheology checks, not just density, are a pro tip.

These DMS equipment components must be correctly sized and integrated. This ensures efficient mineral separation and minimizes DMS cost through effective medium recovery.

Best Ores for DMS & Success Cases?

Dense Medium Separation is highly effective for a variety of ores and materials. The key requirement is a noticeable density difference between the valuable component and the waste. It is particularly suited for pre-concentration or producing a final product.

• Coal Washing:
  • This is one of the largest DMS applications. Clean coal has a lower density (e.g., 1.3-1.7 g/cm³) than the associated shale, sandstone, and pyrite (e.g., >2.0 g/cm³). DMS plants, often using Dense Medium Cyclones or baths, effectively separate coal from these impurities. This increases its calorific value and reduces ash content. The separation density is carefully controlled using magnetite powder suspensions.
• Iron Ore Beneficiation:
  • Many iron ores, like hematite or magnetite, can be upgraded using DMS. High-grade iron minerals are denser than gangue minerals like quartz or silicates. DMS is often used to pre-concentrate coarser fractions of iron ore beneficiation feed. This rejects significant waste before finer grinding and further processing, saving energy and costs. Ferrosilicon is a common medium.
• Diamond Recovery:
  • Diamonds have a density of about 3.52 g/cm³. Associated kimberlite or lamproite gangue minerals are typically less dense (around 2.6-2.8 g/cm³). DMS, using ferrosilicon as the medium, is a primary concentration step in most diamond mines worldwide. It effectively recovers diamonds from large volumes of crushed ore.
• Base Metal Ores (e.g., Lead, Zinc, Copper):
  • Sulfide minerals like galena (lead), sphalerite (zinc), and chalcopyrite (copper) are significantly denser than common gangue minerals (quartz, calcite, feldspar). DMS can be used for pre-concentration, especially for coarser ore fractions. This reduces the tonnage fed to more expensive grinding and flotation circuits.
• Industrial Minerals (e.g., Fluorspar, Barite, Magnesite):
  • DMS is used to upgrade various industrial minerals. For example, fluorspar can be separated from lighter silicates. Barite, with its high density, is easily concentrated. Magnesite can be separated from dolomite or silica.
• Aggregate Purification and Recycling:
  • In the construction industry, DMS can upgrade crushed rock aggregates. It removes deleterious materials like shale, lignite, or porous chert. It is also increasingly used in recycling construction and demolition waste. DMS separates concrete and bricks from lighter contaminants like wood or plastic.

The challenge of “Near-Density Material” (NDM) is a true test for any DMS plant. NDM refers to particles whose density is very close to the target separation density (e.g., ±0.1 SG units). High NDM content demands extremely stable medium conditions and a low Epm (separation precision) value. Even minor upsets can lead to significant losses or product contamination.

Choosing Right Dense Medium: How Critical?

Choosing the right dense medium, such as ferrosilicon or magnetite powder, is absolutely critical for the success and separation efficiency of your Dense Medium Separation plant. The medium’s properties directly influence separation density control, medium stability, viscosity, and medium recovery economics.

• Achievable Separation Density:
  • Ferrosilicon: This is an alloy of iron and silicon. It is available in various grades (e.g., 15% Si, 45% Si). It can create stable suspensions with higher densities (up to ~3.2-3.4 g/cm³ for milled FeSi, and even higher for atomized FeSi). This makes it suitable for separating minerals with higher specific gravities, like diamonds or some base metal ores.
  • Magnetite Powder: This is finely ground iron oxide (Fe₃O₄). It is less dense than ferrosilicon. It typically creates suspensions with densities up to ~2.5-2.8 g/cm³. This makes it ideal for applications like coal washing where lower separation densities are required.
• Viscosity and Rheology:
  • The particle size distribution and shape of the medium solids affect the suspension’s viscosity. Ideally, you want a low-viscosity medium for a given density. This allows for sharper separation and better handling of fine particles.
  • Atomized ferrosilicon (spherical particles) generally produces lower viscosity suspensions compared to milled ferrosilicon (irregular particles) at the same density.
  • Contamination by ore slimes significantly increases medium viscosity. This is the “rheological devil” that can impair separation even if the density gauge reads correctly. The choice of medium must consider the ore’s tendency to produce slimes.
• Medium Stability:
  • A good medium should form a stable suspension that resists settling, especially at lower flow rates. The fineness and particle shape of the medium contribute to stability. However, too many ultra-fines can also increase viscosity.
• Hardness and Abrasion Resistance:
  • The medium undergoes continuous pumping and agitation. It should be hard enough to resist rapid degradation (attrition). Excessive attrition leads to increased medium consumption and the generation of ultra-fine particles that can increase viscosity and be harder to recover.
• Magnetic Susceptibility (for Recovery):
  • Both ferrosilicon and magnetite powder are magnetic. This allows for efficient medium recovery using Magnetic Separators. However, the “selective wear” and “component drift” of the medium can be an issue. The finest, freshest, and often most magnetic particles can be preferentially lost in the recovery circuit if not optimized. Non-magnetic heavy minerals from the ore can also build up in the medium, altering its properties. Regular monitoring of the circulating medium’s magnetic content and particle size is important.
• Cost and Availability:
  • Magnetite powder is generally less expensive than ferrosilicon. Its lower density also means less mass is required per unit volume of medium for lower density applications. Availability can also be a factor depending on your location.

Practical Implications for You:

• For Coal Washing: Magnetite powder is almost universally used due to the lower separation density needed and its lower cost.
• For Diamond/Base Metal/High-Density Ores: Ferrosilicon (often atomized for better rheology) is the standard choice to achieve the necessary higher separation densities.
• Contamination: If your ore produces a lot of fines or clay, this will impact medium performance regardless of type. Effective desliming before DMS is crucial.

Key DMS Parameters for Efficiency?

Optimizing a Dense Medium Separation plant for maximum separation efficiency and precision (often measured by Epm – Ecart Probable moyen) involves careful control of several key process parameters. These parameters interact, so a holistic approach to the DMS process is needed.

• Separation Density (Cut-Point Density):
  • Impact: This is the most fundamental parameter. It dictates which particles float and which sink. Incorrect density leads to misplacement of valuable mineral or unacceptable product contamination.
  • Optimization: Continuously monitor using density gauges. Automatically adjust by adding water or dense medium concentrate. The target density is determined by washability tests on your specific ore.
• Medium Rheology (Viscosity and Yield Stress):
  • Impact: This is the “rheology devil.” High viscosity, often caused by slimes or degraded medium, hinders particle movement. It reduces separation sharpness (higher Epm). Dense particles may be held in the floats; light particles may be dragged to the sinks. Density readings alone don’t show this.
  • Optimization:
    • Effective Feed Desliming: Remove fines before DMS. This is your first line of defense.
    • Medium Cleaning Circuit: Continuously bleed a portion of the medium and clean it (e.g., via fine screens or cyclones) to remove accumulated slimes.
    • Quality of Medium: Use good quality ferrosilicon or magnetite powder with appropriate particle size distribution. Avoid excessive ultra-fines.
    • Monitor Rheology: Periodically measure viscosity (e.g., with a Marsh funnel or viscometer). Don’t rely solely on density. Correlate rheology with performance.
• Medium Stability:
  • Impact: An unstable medium can lead to density gradients within the separating vessel. This results in inconsistent separation.
  • Optimization: Ensure proper agitation in sumps and vessels. Maintain correct medium particle size distribution. The use of appropriate medium types (e.g., atomized vs. milled ferrosilicon) can help.
• Cyclone Inlet Pressure (for DMCs):
  • Impact: This affects the centrifugal forces within the Dense Medium Cyclone, influencing the cut-point density and separation sharpness. Too low pressure results in poor separation. Too high can increase wear and medium degradation.
  • Optimization: Operate within the design range specified by the DMC manufacturer. Monitor pressure and adjust pump speed or control valves. Consistent pressure is key.
• Differential Head (for DMCs):
  • Impact: The pressure difference between the cyclone feed and overflow. This also influences separation performance and the stability of the air core within the cyclone.
  • Optimization: Maintain within recommended limits by adjusting overflow (vortex finder) and underflow (spigot) diameters if necessary, though spigot changes are less common for density control.
• Feed Rate and Solids Concentration:
  • Impact: Overloading the separating vessel can reduce residence time and separation efficiency. Very dilute feeds can also be problematic.
  • Optimization: Maintain a steady feed rate within the design capacity of the DMS equipment.
• Medium-to-Ore Ratio:
  • Impact: Sufficient medium must be present to ensure all particles are effectively suspended and separated.
  • Optimization: Control the flow rates of ore and medium to maintain the design ratio.
• Drain and Rinse Screen Efficiency:
  • Impact: Inefficient rinsing leads to high medium recovery losses. Poor draining can overload the dilute medium circuit. This is beyond simple medium recovery; it’s about medium cleanliness and water balance.
  • Optimization: Ensure adequate, well-distributed spray water. Maintain screen panels. Avoid overloading screens. Monitor the solids content in the dilute medium.
• Water and Slimes Balance:
  • Impact: The “invisible water” from feed, pump glands, etc., and “new slimes” generated in circuit can upset the medium density and viscosity. This is a critical, often overlooked, system stability factor.
  • Optimization: Conduct regular water and solids balance audits. Optimize thickener/clarifier operation in the dilute circuit. Ensure flocculant dosing is correct.

Managing these parameters effectively, often with automated control systems, is crucial for achieving consistent, high separation efficiency in your DMS application.

DMS vs. Jigging/Spirals: Pros & Cons?

Dense Medium Separation offers distinct advantages over other gravity concentration methods like Jigging separation or Spiral Chutes, but it also has its limitations and higher complexity.

Dense Medium Separation (DMS) Advantages:

1. Sharpness of Separation (Low Epm): DMS, especially using Dense Medium Cyclones, can achieve very precise separations. This means a cleaner distinction between valuable minerals and waste, even when density differences are relatively small. This leads to higher recovery of valuables and better product grades. Epm values for DMS are typically much lower (better) than for jigs or spirals.
2. High Unit Capacity: DMS units, particularly DMCs, can process large tonnages of material in a relatively small footprint.
3. Wide Particle Size Range: While fines are removed beforehand, DMS can effectively treat a broader range of particle sizes (e.g., 0.5mm up to 100mm+ in baths) in a single process compared to jigs or spirals which are more size-sensitive.
4. Direct Control of Separation Density: The separation density can be precisely controlled and easily adjusted by changing the medium’s solids concentration. This allows for fine-tuning the separation to match ore characteristics or product requirements.
5. Less Sensitive to Feed Fluctuations (within limits): Well-controlled DMS systems can handle moderate fluctuations in feed grade and composition better than some other gravity methods.

Dense Medium Separation (DMS) Limitations/Disadvantages:

1. Higher Capital Cost: DMS equipment and the overall plant (including medium preparation and recovery circuits) are generally more expensive to install than jigs or spirals.
2. Higher Operating Cost (DMS Cost): The main DMS cost components include medium consumption (ferrosilicon or magnetite powder losses), power for pumping and agitation, and maintenance of more complex circuitry. Medium recovery is vital.
3. Process Complexity: Operating and maintaining a DMS plant requires a higher level of skill and control due to the need to manage the dense medium circuit.
4. Slimes Sensitivity: DMS is very sensitive to slime (-0.5mm or finer particles) contamination in the feed. Extensive desliming is usually required, which adds to cost and complexity. Slimes increase medium viscosity, reducing separation efficiency.
5. Medium Contamination and Degradation: The medium can be contaminated by fine ore particles or degraded by abrasion, requiring cleaning and replenishment.

Separation Method	Advantages	Disadvantages
Jigging Separation	– Lower capital and operating costs.- Simpler operation.- Can handle some clayish/slimy feeds better than DMS (if not excessive).- Effective for coarse particles with significant density differences.	– Less precise separation (higher Epm).- More sensitive to particle size and shape.- Lower capacity per unit compared to DMCs.- Water consumption can be high.
Spiral Separation	– Low capital and operating costs.- Simple to operate, no moving parts.- Low energy consumption.- Effective for fine heavy mineral sands.	– Limited to finer particle sizes (typically <2mm).- Less precise separation than DMS.- Sensitive to feed solids percentage and slime content.- Lower capacity per unit.

When to Choose DMS/DMS is often preferred when:

• A very sharp separation is required to meet product quality specifications.
• The density difference between valuable and waste minerals is not very large.
• High tonnages need to be processed efficiently.
• The value of the mineral justifies the higher DMS cost.

Main DMS Plant Costs (CAPEX & OPEX)?

Investing in and operating a Dense Medium Separation plant involves significant DMS cost components, both for initial capital expenditure (CAPEX) and ongoing operational expenditure (OPEX). Understanding these is crucial for project feasibility.

Capital Expenditure (CAPEX) – Initial Investment:

1. DMS Equipment: This is a major portion.
   • Feed preparation: Crushers, screens (Vibrating Screens), scrubbers.
   • Separating vessels: Dense Medium Cyclones, drums, or baths.
   • Medium handling: Sumps, pumps, Mixer tanks.
   • Product screens: Drain and rinse screens.
   • Medium Recovery circuit: Magnetic Separators, densifying cyclones/thickeners, medium cleaning screens.
2. Ancillary Equipment: Conveyors, piping, electrical systems, instrumentation, and control systems (PLCs).
3. Civil Works and Infrastructure: Foundations, buildings, roads, power supply, water supply, tailings disposal facilities.
4. Engineering and Installation: Plant design, project management, construction, and commissioning.
5. Initial Medium Inventory: The first fill of ferrosilicon or magnetite powder.
6. Spares Inventory: Critical spare parts for key DMS equipment.

Operating Expenditure (OPEX) – Ongoing Costs:

1. Dense Medium Consumption: This is often the single largest OPEX item. It includes losses of ferrosilicon or magnetite powder due to:
   • Adherence to products (even after rinsing).
   • Inefficiencies in the medium recovery circuit.
   • Attrition and degradation of medium particles.
   • Spills.
     Typical losses range from 0.2 to 1.0 kg per ton of feed, depending on the ore and plant efficiency.
2. Power: Consumed by pumps, screens, Magnetic Separators, crushers, and agitators. Pumping dense, sometimes viscous, slurries can be energy-intensive.
3. Labor: Operators, maintenance staff, supervisors, and laboratory personnel.
4. Maintenance and Spares: Replacement of wear parts (screen panels, pump liners, cyclone liners, magnetic separator components), lubricants, and general repairs. The abrasive nature of the ore and medium means regular maintenance is essential.
5. Water: For medium make-up, rinsing, and gland seals. Water treatment and recycling costs may also apply.
6. Reagents (if any): Flocculants for water clarification in the dilute medium circuit.
7. Laboratory and Quality Control: Sampling, analysis of feed, products, and medium.
8. Environmental Compliance: Tailings management, water discharge monitoring.

The specific DMS cost will vary greatly depending on plant size, location, ore type (abrasiveness, slime content), degree of automation, and local costs for labor, power, and supplies. Efficient medium recovery and minimizing medium degradation are paramount for controlling OPEX.

When is DMS Not Ideal/Needs Combos?

While Dense Medium Separation is a powerful mineral separation tool, it’s not universally applicable or always the most economical choice. There are situations where DMS might be unsuitable, or it may need to be combined with other processes.

When DMS Might Not Be Optimal:

• Very Fine Particle Sizes (<0.5mm):
  • DMS, especially Dense Medium Cyclones, becomes less efficient and more problematic with very fine feeds. Medium viscosity increases dramatically with fines, and achieving sharp separations is difficult. Processes like flotation (Flotation Machines), enhanced gravity separators (e.g., Knelson, Falcon), or Shaking Tables are often better for fines.
• Very Small Density Differences:
  • If the density difference between the valuable mineral and gangue is extremely small (e.g., <0.1 g/cm³), even DMS might struggle to achieve a clean separation or may require exceptionally stable and low-viscosity medium, which can be hard to maintain.
• Ore with Excessive Slimes or Clays:
  • If an ore generates a very high percentage of natural slimes or contains swelling clays, the cost and complexity of feed preparation (desliming) and managing medium contamination can make DMS uneconomical. The “rheological devil” of high viscosity due to slimes becomes a major issue.
• Low-Value Commodities with Small Margins:
  • For some very low-value bulk materials, the higher CAPEX and OPEX of a DMS plant (especially DMS cost related to medium) might not be justified. Simpler, cheaper methods like screening or basic Jigging separation might be preferred, even if less efficient.
• Very Small Tonnage Operations:
  • The complexity and scale of even a small DMS plant might not be suitable for very small-scale mining operations.

When DMS Needs to Be Combined with Other Processes（DMS is often part of a larger mineral processing flowsheet）:

• Pre-concentration: DMS can be used to reject a significant portion of barren waste from coarser ore fractions. This reduces the load on downstream grinding and concentration circuits (e.g., flotation, magnetic separation). This is a common DMS application in base metal and iron ore beneficiation.
• Treating Different Size Fractions:
  • A common strategy is to use DMS for coarser particles (e.g., +1mm to -50mm). Finer particles (-1mm +0.1mm) might be treated by spirals or fine gravity separators. Very fine particles (-0.1mm) could go to flotation.
• Cleaning Concentrates from Other Processes:
  • Sometimes, a concentrate produced by another method (e.g., gravity or magnetic) might be further upgraded using DMS to remove near-density contaminants.
• Handling Near-Density Material (NDM) Challenges:
  • If an ore has a high proportion of NDM, DMS might be the primary separator. However, if the NDM fraction itself contains intergrown particles, further Crushing and re-processing (perhaps even by different methods) of a middlings stream from DMS might be necessary.

The decision involves careful metallurgical test work, economic evaluation, and consideration of the entire processing chain.

Testing Material Suitability for DMS?

Evaluating whether your ore or material is suitable for Dense Medium Separation requires thorough laboratory and pilot-scale testing. This will determine the mineral separation characteristics and provide data for DMS equipment selection and plant design.

DMS FAQs

Question 1: What is the typical Epm value I can expect from a DMS plant?
A well-designed and operated Dense Medium Separation plant, especially using Dense Medium Cyclones, can achieve Epm (Ecart Probable moyen, a measure of separation precision) values typically ranging from 0.02 to 0.05 g/cm³. Lower Epm values indicate a sharper, more efficient separation. The actual Epm depends on ore characteristics (especially NDM), particle size, medium quality, and operational control.
Question 2: How much ferrosilicon or magnetite powder might a DMS plant consume?
Medium consumption is a key DMS cost. For ferrosilicon, losses typically range from 0.2 kg to 0.8 kg per ton of plant feed. For magnetite powder in coal washing, losses can be similar, perhaps 0.3 kg to 1.0 kg per ton of feed. These losses depend heavily on ore abrasiveness, screen rinsing efficiency, medium recovery circuit performance, and general plant housekeeping.
Question 3: Can DMS be used for dry processing?
No, traditional Dense Medium Separation is a wet process. It relies on creating a fluid suspension of fine heavy particles (like ferrosilicon or magnetite powder) in water. There are some dry “density-based” separation technologies (e.g., air tables, magnetic density separators for some specific applications), but they operate on different principles than wet DMS.
Question 4: What is the smallest particle size effectively treated by DMS?
Generally, DMS is effective down to about 0.5 mm (500 microns). Below this size, medium viscosity effects become very pronounced, making sharp separations difficult and medium recovery more challenging. Specialized fine coal DMCs might operate slightly finer. For particles smaller than 0.5mm, other mineral separation methods like spirals or flotation are usually preferred.

Summary & Next Steps

Dense Medium Separation (DMS) is a highly effective and precise mineral separation technique. It is ideal for ores with distinct density differences, such as in coal washing or iron ore beneficiation. Success hinges on understanding your ore through thorough testing. It also depends on selecting appropriate DMS equipment, particularly the separating vessel (like a Dense Medium Cyclone) and the medium recovery circuit. Careful management of the dense medium, typically ferrosilicon or magnetite powder, is critical for controlling the separation density and overall DMS cost. While DMS offers sharp separations, its sensitivity to slimes and higher operational complexity mean it’s not a universal solution. Addressing hidden challenges like medium rheology (“rheology devil”), selective medium wear, and circuit balances is key to efficiency.
If you believe Dense Medium Separation could benefit your operation, your next step should be detailed metallurgical test work. This will determine your material’s suitability and provide the data for a robust plant design. Partnering with an experienced provider like ZONEDING, who understands the nuances of the DMS process and equipment, can guide you to a profitable outcome.

About ZONEDING

ZONEDING is your expert partner for comprehensive Dense Medium Separation solutions. With insights into 2025 mineral processing trends and years of manufacturing experience, ZONEDING can provide everything from initial metallurgical testing support and custom DMS plant design to the supply of high-quality DMS equipment. This includes Dense Medium Cyclones, screens, Magnetic Separators, and complete medium circuits. ZONEDING teams are dedicated to delivering efficient and cost-effective Dense Medium Sorting systems that maximize your separation efficiency and adhere to the highest operational standards.
Explore how ZONEDING can optimize your mineral separation project. Contact our DMS specialists today to discuss your specific needs and how our DMS technology can work for you!

Last Updated: March 2025