An Integrated Separation Approach for Beneficiation of Low-Grade Iron Ore

Iron ore beneficiation is crucial for sustainable utilization of low-grade iron ores. Conventional separation methods often fail to efficiently upgrade the iron ores containing complex mineral phases, such as hematite, goethite, ankerite, and limonite. This study evaluated an integrated roasting–leaching–magnetic separation approach applied to an iron ore. Roasting at 800 °C for 90 min significantly enhanced the Fe(II) content and improved magnetic susceptibility, facilitating superior iron-containing minerals separation efficiency. Furthermore, sulfuric acid leaching effectively eliminated non-magnetic impurities such as calcite, improving iron recovery. Davis tube recovery experiments confirmed that this combination markedly enhanced weight recovery (Rw) and iron recovery (Rg), outperforming traditional methods. The findings highlight the synergistic effect of roasting and leaching for refining iron ores and propose an optimized beneficiation strategy. This approach offers an effective method for processing complex iron ores, particularly those with low Fe grade and challenging impurities, improving beneficiation efficiency and mineral extraction.