In 2024, Kumba Iron Ore announced the adoption of ultra-high-dense-media-separation (UHDMS) technology at its Sishen mine in South Africa, investing ZAR11.2 billion to upgrade its dense-media-separation (DMS) plant. UHDMS significantly expands the range of density separation by operating above 4.0 g/cm³, using nitrogen gas-atomised ferrosilicon for efficient separation at higher densities. Each module features multiple high-capacity cyclones, allowing sharper differentiation between iron ore and waste, enabling processing of lower-grade ore and enhancing product quality.
The new system lowers the mining cut-off grade from around 48% Fe to 40%, increasing premium product output from 18% to about 55%. Processing efficiency improvements reduce the strip ratio and waste, cut costs, and allow continued operation during phased, modular installation. UHDMS also aligns with steel industry trends favoring higher Fe content, supporting longer mine life to at least 2044.
Kumba developed the UHDMS technology internally, piloting it successfully before full-scale implementation. Phased conversion began after capital approval in 2024, with the first module expected online in 2026 and full ramp-up by 2028, maintaining consistent production throughout the transition.
