Exploring the lifecycle of ferrosilicon for dense media separation in Botswana mining sector: A brief overview

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.