Due to the rapid depletion of high-grade iron ore resources and exponential demand from the global steel industry, particularly in India targeting 300 MTPA by 2025, the utilization of low-grade iron ores including Banded Hematite Quartzite (BHQ), Banded Hematite Jasper (BHJ), and lateritic iron ores has become critically important. These ores contain 30–50% Fe with associated gangue minerals such as SiO₂ (40–50%), Al₂O₃ (0.5–2.5%), and minor constituents including goethite, magnetite, kaolinite, and gibbsite. This comprehensive review synthesizes conventional beneficiation methods (gravity separation, magnetic separation, flotation) and advanced techniques like reduction roasting to provide systematic approaches for maximizing iron recovery while maintaining economic viability. Case studies demonstrate that integrated mineral characterization followed by optimized beneficiation circuits can achieve pellet-grade concentrates (>64% Fe) with recovery rates of 35–93% depending on ore type and processing route. This paper provides practitioners and researchers with practical guidance on flowsheet design, parameter optimization, and selection of appropriate beneficiation technologies for low-grade iron ore utilization in Indian context and globally.

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1. National Steel Policy. New Delhi: Ministry of Steel, Government of India; 2017. Available from: https://steel.gov.in/sites/default/files/draft-national-steel-policy-2017.pdf.
2. Indian Bureau of Mines. Iron and steel vision 2020. Nagpur: Indian Bureau of Mines; 2013. Available from: https://ibm.nic.in/writereaddata/files/06062017100632Iron%20and%20Steel%202020_P.pdf.
3. Agasnalli C, Lakkundi TK, Natikar RD, Nerlikar D. A study of banded hematite quartzite (BHQ) in Mallasamudra area, Gadag Schist Belt, Karnataka, India. J Mines Met Fuels. 2023;71(12):2426-32. doi:10.18311/jmmf/2023/35225.
4. Sahu SN, Sharma K, Barma SD, Pradhan P, Nayak BK, Biswal SK. Utilization of low-grade BHQ iron ore by reduction roasting followed by magnetic separation for the production of magnetite-based pellet feed. Metall Res Technol. 2019;116(6):611. doi:10.1051/metal/2019039.
5. Nanda SK, Pani S, Beura D. Recovery of iron values through conventional beneficiation techniques from banded hematite jasper of Eastern India with special reference to mineralogical and chemical characterization. Indian J Sci Technol. 2020;13(38):3960–9. doi:10.17485/IJST/v13i38.681.
6. Byra Reddy Raghunatha R, Vardhan H, Arya SB, Hanumanthappa H, Shanmugam BK. Development of beneficiation circuit for low-grade laterite iron ores sourced from the Gujarat area. Disaster Adv. 2025;18(5):177–85. doi:10.25303/185da1770185.
7. Das B, Mishra BK, Prakash S, Das SK, Reddy PSR, Angadi SI. Magnetic and flotation studies of banded hematite quartzite (BHQ) ore for the production of pellet grade concentrate. Int J Miner Metall Mater. 2010;17(6):675–82. doi:10.1007/s12613-010-0373-x.
8. Rath SS, Sahoo H, Singh S, Palei BB, Das B. Separation of hematite from banded hematite jasper (BHJ) by magnetic coating. J Cent South Univ. 2015;22(2):437-44. doi:10.1007/s11771-015-2540-8.
9. Das SK, Prasad R, Singh RP. Characterisation-assisted reduction roasting of BHJ, West Singhbhum, Jharkhand, India. Trans Indian Inst Met. 2018;71(6):1357–62. doi:10.1007/s12666-017-1270-z.
10. Clout JM, Manuel JR. Mineralogical, chemical, and physical characteristics of iron ore. In: Lu L, editor. Iron ore. Cambridge: Woodhead Publishing; 2015. p. 45–84.
11. Kawatra SK, Halt JA. Binding effects in hematite and magnetite concentrates. Int J Miner Process. 2011;99(1-4):39-42. doi:10.1016/j.minpro.2011.03.001.
12. Dey S, Mohanta MK, Singh R. Mineralogy and textural impact on beneficiation of goethitic ore. Int J Min Sci Technol. 2017;27(3):445–50. doi:10.1016/j.ijmst.2017.03.001.
13. Mohanraj GT, Rahman MR, Joladarashi S, Hanumanthappa H, Shanmugam BK, Vardhan H, et al. Design and fabrication of optimized magnetic roller for permanent roll magnetic separator (PRMS): finite element method magnetics (FEMM) approach. Adv Powder Technol. 2021;32(2):546–64. doi:10.1016/j.apt.2020.11.024.
14. Santosh T, Angadi SI, Dash N, Eswaraiah C, Tripathy SK. Characterization and comminution studies of low-grade Indian iron ores. Min Metall Explor. 2019;36(2):303-12. doi:10.1007/s42461-019-0026-1.
15. Richards RG, MacHunter DM, Gates PJ, Palmer MK. Gravity separation of ultra-fine (-0.1 mm) minerals using spiral separators. Miner Eng. 2000;13(1):65–77. doi:10.1016/S0892-6875(99)00160-9.
16. Seifelnassr AAS, Moslim EM, Abouzeid AZM. Effective processing of low-grade iron ore through gravity and magnetic separation techniques. Physicochem Probl Miner Process. 2012;48:567–78.
17. O’Conner M, MacHunter RM. A review of current iron ore processing practices for −8 mm material. In: Proceedings of the Workshop on Iron Ore Beneficiation; 2006. p. 1–5.
18. Manuel JR, Clout JM. Goethite classification, distribution and properties with reference to Australian iron deposits. In: Proceedings of Iron Ore 2017; 2017. p. 567–74.
19. Akbari H, Noaparast M, Shafaei SZ, Hajati A, Aghazadeh S, Akbari H. A beneficiation study on a low grade iron ore by gravity and magnetic separation. Russ J Nonferrous Met. 2018;59(4):353-63. doi:10.1134/S0036029518040020.
20. Das B, Rath SS. Existing and new processes for beneficiation of Indian iron ores. Trans Indian Inst Met. 2020;73(3):505-14. doi:10.1007/s12666-019-01795-x.
21. Zhang X, Gu X, Han Y, Parra-Álvarez N, Claremboux V, Kawatra SK. Flotation of iron ores: a review. Miner Process Extr Metall Rev. 2021;42(3):184–212. doi:10.1080/08827508.2019.1689494.

Due to the rapid depletion of high-grade iron ore resources and exponential demand from the global steel industry, particularly in India targeting 300 MTPA by 2025, the utilization of low-grade iron ores including Banded Hematite Quartzite (BHQ), Banded Hematite Jasper (BHJ), and lateritic iron ores has become critically important. These ores contain 30–50% Fe with associated gangue minerals such as SiO₂ (40–50%), Al₂O₃ (0.5–2.5%), and minor constituents including goethite, magnetite, kaolinite, and gibbsite. This comprehensive review synthesizes conventional beneficiation methods (gravity separation, magnetic separation, flotation) and advanced techniques like reduction roasting to provide systematic approaches for maximizing iron recovery while maintaining economic viability. Case studies demonstrate that integrated mineral characterization followed by optimized beneficiation circuits can achieve pellet-grade concentrates (>64% Fe) with recovery rates of 35–93% depending on ore type and processing route. This paper provides practitioners and researchers with practical guidance on flowsheet design, parameter optimization, and selection of appropriate beneficiation technologies for low-grade iron ore utilization in Indian context and globally.

🔒 This is a subscription article

Full text is available to subscribers and institutional members. Please choose an option below to access it.

1. National Steel Policy. New Delhi: Ministry of Steel, Government of India; 2017. Available from: https://steel.gov.in/sites/default/files/draft-national-steel-policy-2017.pdf.
2. Indian Bureau of Mines. Iron and steel vision 2020. Nagpur: Indian Bureau of Mines; 2013. Available from: https://ibm.nic.in/writereaddata/files/06062017100632Iron%20and%20Steel%202020_P.pdf.
3. Agasnalli C, Lakkundi TK, Natikar RD, Nerlikar D. A study of banded hematite quartzite (BHQ) in Mallasamudra area, Gadag Schist Belt, Karnataka, India. J Mines Met Fuels. 2023;71(12):2426-32. doi:10.18311/jmmf/2023/35225.
4. Sahu SN, Sharma K, Barma SD, Pradhan P, Nayak BK, Biswal SK. Utilization of low-grade BHQ iron ore by reduction roasting followed by magnetic separation for the production of magnetite-based pellet feed. Metall Res Technol. 2019;116(6):611. doi:10.1051/metal/2019039.
5. Nanda SK, Pani S, Beura D. Recovery of iron values through conventional beneficiation techniques from banded hematite jasper of Eastern India with special reference to mineralogical and chemical characterization. Indian J Sci Technol. 2020;13(38):3960–9. doi:10.17485/IJST/v13i38.681.
6. Byra Reddy Raghunatha R, Vardhan H, Arya SB, Hanumanthappa H, Shanmugam BK. Development of beneficiation circuit for low-grade laterite iron ores sourced from the Gujarat area. Disaster Adv. 2025;18(5):177–85. doi:10.25303/185da1770185.
7. Das B, Mishra BK, Prakash S, Das SK, Reddy PSR, Angadi SI. Magnetic and flotation studies of banded hematite quartzite (BHQ) ore for the production of pellet grade concentrate. Int J Miner Metall Mater. 2010;17(6):675–82. doi:10.1007/s12613-010-0373-x.
8. Rath SS, Sahoo H, Singh S, Palei BB, Das B. Separation of hematite from banded hematite jasper (BHJ) by magnetic coating. J Cent South Univ. 2015;22(2):437-44. doi:10.1007/s11771-015-2540-8.
9. Das SK, Prasad R, Singh RP. Characterisation-assisted reduction roasting of BHJ, West Singhbhum, Jharkhand, India. Trans Indian Inst Met. 2018;71(6):1357–62. doi:10.1007/s12666-017-1270-z.
10. Clout JM, Manuel JR. Mineralogical, chemical, and physical characteristics of iron ore. In: Lu L, editor. Iron ore. Cambridge: Woodhead Publishing; 2015. p. 45–84.
11. Kawatra SK, Halt JA. Binding effects in hematite and magnetite concentrates. Int J Miner Process. 2011;99(1-4):39-42. doi:10.1016/j.minpro.2011.03.001.
12. Dey S, Mohanta MK, Singh R. Mineralogy and textural impact on beneficiation of goethitic ore. Int J Min Sci Technol. 2017;27(3):445–50. doi:10.1016/j.ijmst.2017.03.001.
13. Mohanraj GT, Rahman MR, Joladarashi S, Hanumanthappa H, Shanmugam BK, Vardhan H, et al. Design and fabrication of optimized magnetic roller for permanent roll magnetic separator (PRMS): finite element method magnetics (FEMM) approach. Adv Powder Technol. 2021;32(2):546–64. doi:10.1016/j.apt.2020.11.024.
14. Santosh T, Angadi SI, Dash N, Eswaraiah C, Tripathy SK. Characterization and comminution studies of low-grade Indian iron ores. Min Metall Explor. 2019;36(2):303-12. doi:10.1007/s42461-019-0026-1.
15. Richards RG, MacHunter DM, Gates PJ, Palmer MK. Gravity separation of ultra-fine (-0.1 mm) minerals using spiral separators. Miner Eng. 2000;13(1):65–77. doi:10.1016/S0892-6875(99)00160-9.
16. Seifelnassr AAS, Moslim EM, Abouzeid AZM. Effective processing of low-grade iron ore through gravity and magnetic separation techniques. Physicochem Probl Miner Process. 2012;48:567–78.
17. O’Conner M, MacHunter RM. A review of current iron ore processing practices for −8 mm material. In: Proceedings of the Workshop on Iron Ore Beneficiation; 2006. p. 1–5.
18. Manuel JR, Clout JM. Goethite classification, distribution and properties with reference to Australian iron deposits. In: Proceedings of Iron Ore 2017; 2017. p. 567–74.
19. Akbari H, Noaparast M, Shafaei SZ, Hajati A, Aghazadeh S, Akbari H. A beneficiation study on a low grade iron ore by gravity and magnetic separation. Russ J Nonferrous Met. 2018;59(4):353-63. doi:10.1134/S0036029518040020.
20. Das B, Rath SS. Existing and new processes for beneficiation of Indian iron ores. Trans Indian Inst Met. 2020;73(3):505-14. doi:10.1007/s12666-019-01795-x.
21. Zhang X, Gu X, Han Y, Parra-Álvarez N, Claremboux V, Kawatra SK. Flotation of iron ores: a review. Miner Process Extr Metall Rev. 2021;42(3):184–212. doi:10.1080/08827508.2019.1689494.