The beneficiation of low-grade iron ores is a key research and development topic in the mineral processing industry. The gradual exhaustion of high-grade iron ore reserves, and rising consumer iron and steel demand globally necessitate efficient low-quality iron ore beneficiation to meet steelmaking quality requirements. This comprehensive review explores various beneficiation techniques for low-quality iron ore, focusing on conventional methods including comminution, froth flotation and gravity separation. This article discusses the principles, processes, and equipment used in these techniques and highlights recent advancements and research efforts in the field. This review also emphasizes the importance of effective beneficiation processes in enhancing economic viability, sustainable resource management, and environmental conservation. Furthermore, it presents a case study of iron ore deposits in Botswana, highlighting the potential economic growth and sustainable development that can be achieved by maximizing resource utilization through reductive roasting, followed by magnetic separation of iron ore using semi-bituminous coal as a reductant. Overall, this review provides valuable insights into low-grade iron ore beneficiation techniques and their significance in meeting the growing demand for high-quality iron and steel products.

The contemporary research article is central to understanding coal structure evaluation and the morphological development impacting its utilization in different applications. Through Mineral Liberation Analysis (MLA) designs high content phyllosilicates minerals and swelling clay minerals were rationalized to provides a novel insight into enhanced coal beneficiation and the benefits of coal by-product re-utilization progressions that encourage safer environments and economic sustainability. This work commences with collection of five (5) different coal samples from the central district region in Botswana, sample characterization deploying Thermogravimetric coal analysis (TGA), x-ray fluorescence spectroscopy (XRF), x-ray diffraction (XRD), scanning electron microscopy (SEM) and the Hardgrove Grindability Index (HGI) test that was directed to quantification of the coal hardness and fracture toughness during milling. The cumulative objective was to understand the correlation that exists between the natural composition of the coal sample and their adaptation and application in various carbonaceous products. A solid connection was thus identified in the sulfur and phosphorus weight percentage inclusions in all the coal materials hence higher significance in sphalerite mineral phases (Zn, Fe) S critically increased the fracture toughness and hardness properties. Moreover, mineral amalgams intrinsic to the coal maceral such as aluminum oxides (Al₂O₃), silicate (SiO₂), calcites (CaO), Iron oxide (Fe₂O₃), potassium feldspars (K − AlSi₃O₈), albite (Na − AlSi₃O₈), and anorthite (Ca − Al₂Si₂O₈) compounds in alkali feldspars were detected in larger quantities. The coal industry has attracted much industrial attention to manufacturing foundations producing cement, ceramic tiles, paving bricks, and material synthesis and will continue to supply other economic sectors in the conceivable future. Graphical Abstract