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A Review of Beneficiation Practices in the United States
Iron Ore Industry
Jestos Taguta, Shashi Rao, Sunil Kumar Tripathy, Lysa Chizmadia, Matt Mlinar
Minerals Processing &Metallurgy Research Group, Natural Resources Research Institute, University of Minnesota
ABSTRACT: In 2022, the U.S. iron ore industry produced 46 Mt of iron ore concentrate, primarily driven by
the Mesabi and Marquette Ranges in Minnesota and Michigan, respectively. Notably, seven processing facilities
contributed 98% of usable iron ore. The iron ores in the US are highly variable in mineralogy, necessitating
tailored processing strategies for each type.
This paper provides a detailed overview of the evolution, challenges, and opportunities for the iron ore industry
in the U.S. A detailed review and comparison of the mineralogy, and beneficiation strategies for the different
iron ores in the U.S. is also presented. Processing methodologies have evolved from direct shipping of high-
grade iron ores to complex beneficiation flowsheets to process low-grade, mineralogically complex iron ores,
with oxidized magnetite, goethite, and siderite. The challenges associated with the declining ore grades, min-
eralogically complex ores and stringent environmental regulations have pushed the iron ore industry to seek
sustainable processes and technologies such as fine processing, selective flocculation, and flotation along with
dewatering options. The success of the future iron ore industry hinges on historical tailings and mine overbur-
den reprocessing, the adoption of emerging and sustainable technologies to not only improve energy, water, and
metallurgical efficiencies, but also produce high-quality concentrate for advanced iron-making techniques, such
as hydrogen direct reduction and direct smelting.
INTRODUCTION
In 2022, the U.S. iron ore industry produced 46 Mt of
iron ore concentrate, primarily driven by the Mesabi and
Marquette Ranges in Minnesota and Michigan, respec-
tively. Notably, seven processing facilities contributed 98%
of usable iron ore (Tuck, 2023). Over the years, Minnesota’s
Mesabi Iron Range has produced around 1.6 billion tons
of high-grade iron ore pellets annually, contributing to
approximately 75% of the total U.S. iron ore production.
The mining operations in the state of Minnesota alone have
a capacity of over 40 million tons per year. Table 1 shows
the major iron mining operations currently active in the
USA.
The distribution of the iron mines and processing
plants on the Mesabi Iron Range is depicted in Figure 1.
IRON ORE BENEFICIATION IN THE U.S.
Direct shipping ores
The USA iron ore processing flowsheets have evolved from
direct shipping operations (DSO) of high-grade iron ores to
complex flowsheets for processing low-grade taconite mag-
netic and hematite ores. Iron ore mining in Minnesota’s
Mesabi Iron Range dates to over 120 years. Initially, min-
ing focused on direct shipping ores, which were rich in iron
after oxidation processes, with at least 55% Fe grade. The
DSO process, depicted in Figure 2, involved crushing and
A Review of Beneficiation Practices in the United States
Iron Ore Industry
Jestos Taguta, Shashi Rao, Sunil Kumar Tripathy, Lysa Chizmadia, Matt Mlinar
Minerals Processing &Metallurgy Research Group, Natural Resources Research Institute, University of Minnesota
ABSTRACT: In 2022, the U.S. iron ore industry produced 46 Mt of iron ore concentrate, primarily driven by
the Mesabi and Marquette Ranges in Minnesota and Michigan, respectively. Notably, seven processing facilities
contributed 98% of usable iron ore. The iron ores in the US are highly variable in mineralogy, necessitating
tailored processing strategies for each type.
This paper provides a detailed overview of the evolution, challenges, and opportunities for the iron ore industry
in the U.S. A detailed review and comparison of the mineralogy, and beneficiation strategies for the different
iron ores in the U.S. is also presented. Processing methodologies have evolved from direct shipping of high-
grade iron ores to complex beneficiation flowsheets to process low-grade, mineralogically complex iron ores,
with oxidized magnetite, goethite, and siderite. The challenges associated with the declining ore grades, min-
eralogically complex ores and stringent environmental regulations have pushed the iron ore industry to seek
sustainable processes and technologies such as fine processing, selective flocculation, and flotation along with
dewatering options. The success of the future iron ore industry hinges on historical tailings and mine overbur-
den reprocessing, the adoption of emerging and sustainable technologies to not only improve energy, water, and
metallurgical efficiencies, but also produce high-quality concentrate for advanced iron-making techniques, such
as hydrogen direct reduction and direct smelting.
INTRODUCTION
In 2022, the U.S. iron ore industry produced 46 Mt of
iron ore concentrate, primarily driven by the Mesabi and
Marquette Ranges in Minnesota and Michigan, respec-
tively. Notably, seven processing facilities contributed 98%
of usable iron ore (Tuck, 2023). Over the years, Minnesota’s
Mesabi Iron Range has produced around 1.6 billion tons
of high-grade iron ore pellets annually, contributing to
approximately 75% of the total U.S. iron ore production.
The mining operations in the state of Minnesota alone have
a capacity of over 40 million tons per year. Table 1 shows
the major iron mining operations currently active in the
USA.
The distribution of the iron mines and processing
plants on the Mesabi Iron Range is depicted in Figure 1.
IRON ORE BENEFICIATION IN THE U.S.
Direct shipping ores
The USA iron ore processing flowsheets have evolved from
direct shipping operations (DSO) of high-grade iron ores to
complex flowsheets for processing low-grade taconite mag-
netic and hematite ores. Iron ore mining in Minnesota’s
Mesabi Iron Range dates to over 120 years. Initially, min-
ing focused on direct shipping ores, which were rich in iron
after oxidation processes, with at least 55% Fe grade. The
DSO process, depicted in Figure 2, involved crushing and