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Modular DMS · Dense media separation

Modular DMS plants for mining

Pre-engineered modular dense media separation packages from 5 tph to 200 tph — faster to deploy, clearer in commercial scope, and suited to remote and phased projects across Southern Africa.

Discuss a modular DMS plant
  • 5–200 tph capacity range
  • Pre-engineered modules
Modular dense media separation (DMS) plant for mineral processing in Southern Africa

Why modular DMS

Dense media separation without open-ended site construction

Dense media separation remains one of the most effective gravity-based methods for pre-concentration and beneficiation. Modular DMS packages bring the same process fundamentals into a form that suits mining projects: controlled workshop fabrication, efficient logistics, shorter site programmes and package-oriented commercial scope.

Plants are configured around feed characteristics, cut-point and throughput — not a fixed catalogue model. Capacity is offered from 5 tonnes per hour to 200 tonnes per hour, so projects can start at the right scale and expand with parallel modules when duty and capital allow.

All package plant types
Crushing and screening plant with radial conveyors discharging to crushed-rock stockpiles

Capacity

5–200 tph

Single packages or phased parallel modules

Delivery model

Modular package

Pre-engineered modules, factory assembly focus

Operating context

Southern Africa

Remote sites, phased projects, clearer capital exposure

Process intent

When modular DMS is the right choice

Choose dense media separation when feed density differences drive recovery — copper, coal, diamonds, iron ore or manganese — and you need a pre-engineered package from roughly 5 to 200 tph rather than a stick-built plant.

  1. 1Feed preparation
  2. 2Dense medium circuit
  3. 3Cyclone / drum separation
  4. 4Medium recovery
  5. 5Product & reject handling

Typical applications

Where modular DMS is commonly applied

Modular dense media separation packages support a wide range of commodities. Exact circuit selection depends on particle size, near-density material, clay content and product specifications.

  • Copper

    Density-based separation of copper-bearing material where near-density control and consistent media recovery are critical to yield.

  • Coal

    Dense medium circuits for coal cleaning and product quality control, configured for duty and plant layout constraints.

  • Diamonds

    DMS concentration stages in diamond recovery trains, with modular packages suited to remote deposits and phased expansion.

  • Iron ore

    Pre-concentration and beneficiation applications where dense media separation improves feed grade ahead of downstream processing.

  • Manganese

    Density separation packages for manganese ores where cut-point stability and operable plant design support project economics.

  • Other density-suitable ores

    Base-metal and industrial mineral applications where dense media separation is metallurgically appropriate — confirmed through ore characterisation.

Key components

What a modular DMS plant typically includes

Packages are assembled from proven process blocks — cyclones, densifiers, magnetic separators, media recovery and screening — arranged for modular transport, assembly and operable maintenance. Exact equipment selection follows ore characterisation and duty.

Modular dense media separation (DMS) plant for mineral processing in Southern Africa

  • Dense medium cyclones

    Primary separation units sized for duty and cut-point, forming the core of the dense medium circuit.

  • Densifiers

    Media densification stages that maintain stable circuit density for consistent separation performance.

  • Magnetic separators

    Ferrosilicon or magnetite media recovery equipment that protects operating cost and circuit stability.

  • Media recovery circuit

    Integrated recovery and recirculation of dense medium so media losses and make-up costs stay under control.

  • Screens

    Feed preparation, drain-and-rinse and product screens that protect cyclone performance and product quality.

  • Pumps, piping & controls

    Slurry handling, media transfer and control philosophy defined as part of the modular package interfaces.

Benefits of the modular approach

Practical advantages for project delivery

Modularisation does not replace process engineering — it packages proven dense media separation into a form that is faster, more predictable and easier to phase on site.

  • Speed of deployment

    Pre-engineered modular packages shorten the path from order to first production compared with fully stick-built DMS plants of similar duty.

  • Reduced on-site civils

    Workshop-focused fabrication and modular layouts limit open-ended civil works and site construction risk.

  • Scalability

    Start within the 5–200 tph range and add parallel modules as throughput, market or resource definition improves.

  • Relocatable capacity

    Modular packages can support relocation or redeployment when project economics or ore sources change.

  • Suited to mining sites

    Logistics, access and phased capital realities of regional mining projects are reflected in the modular approach.

Design fundamentals still apply

Successful modular DMS depends on ore characterisation (including near-density material and clay content), correct cut-point control, efficient media recovery, adequate surge capacity and competent screening ahead of the dense medium circuit. Packages are configured around those fundamentals — not sold as fixed model numbers.

DMS plant enquiry

Ready to discuss a modular DMS package?

Share commodity, feed size, target throughput (within 5–200 tph), site constraints and programme. We will help scope a practical modular dense media separation package for mining conditions.

Discuss modular DMS requirements

· Heidelberg, Gauteng · South Africa

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