TY - JOUR
T1 - Exploring the lifecycle of ferrosilicon for dense media separation in Botswana mining sector
T2 - A brief overview
AU - Sebobi, Phemo T.
AU - Obadele, Babatunde Abiodun
AU - Raghupatruni, Prasad
AU - Ogunmuyiwa, Enoch Nifise
N1 - Publisher Copyright:
© 2025 The Author(s)
PY - 2026/3
Y1 - 2026/3
N2 - Ferrosilicon (FeSi), a metallic alloy of iron (Fe) and silicon (Si) has been a critical component in Dense Medium Separation (DMS) processes since the 1950s in the mineral processing industry. Since then, FeSi has been utilized to separate various minerals such as diamonds, gold, tin, tungsten, and iron from less valuable material, i.e. gangue. The use of FeSi as a separation medium remains prominent today. This review provides a comprehensive analysis of FeSi's lifecycle in DMS, from production using the electric submerged arc furnace to its role in ensuring separation efficiency, medium stability, and loss mitigation strategies. Key factors affecting FeSi performance, such as viscosity, stability, contamination, and corrosion, are explored, along with emerging techniques for improving its sustainability and cost-effectiveness. Additionally, this paper proposes a case study on the potential for FeSi production in Botswana, leveraging local raw materials such as iron ore and silica to support economic growth. Future advancements in FeSi recovery and process optimization are also discussed. By addressing quality standards, environmental considerations, and economic feasibility, this review aims to provide a valuable reference for researchers and industry professionals seeking to enhance the efficiency and longevity of FeSi in DMS applications.
AB - Ferrosilicon (FeSi), a metallic alloy of iron (Fe) and silicon (Si) has been a critical component in Dense Medium Separation (DMS) processes since the 1950s in the mineral processing industry. Since then, FeSi has been utilized to separate various minerals such as diamonds, gold, tin, tungsten, and iron from less valuable material, i.e. gangue. The use of FeSi as a separation medium remains prominent today. This review provides a comprehensive analysis of FeSi's lifecycle in DMS, from production using the electric submerged arc furnace to its role in ensuring separation efficiency, medium stability, and loss mitigation strategies. Key factors affecting FeSi performance, such as viscosity, stability, contamination, and corrosion, are explored, along with emerging techniques for improving its sustainability and cost-effectiveness. Additionally, this paper proposes a case study on the potential for FeSi production in Botswana, leveraging local raw materials such as iron ore and silica to support economic growth. Future advancements in FeSi recovery and process optimization are also discussed. By addressing quality standards, environmental considerations, and economic feasibility, this review aims to provide a valuable reference for researchers and industry professionals seeking to enhance the efficiency and longevity of FeSi in DMS applications.
KW - Dense medium separation
KW - Milled ferrosilicon
KW - Rheology
KW - Specific gravity
KW - Sustainability
UR - https://www.scopus.com/pages/publications/105024253747
U2 - 10.1016/j.sciaf.2025.e03116
DO - 10.1016/j.sciaf.2025.e03116
M3 - Review article
AN - SCOPUS:105024253747
SN - 2468-2276
VL - 31
JO - Scientific African
JF - Scientific African
M1 - e03116
ER -