Integrated approach for Mont Reed iron ore: From characterization to ore processing

This study presents a comprehensive technological characterization and preliminary beneficiation strategy for a low-grade iron ore from Quebec, Canada, aimed at producing direct reduction (DR) quality concentrate. The novelty of this work lies in its integrated characterization-to-processing approach applied to an unexploited, geologically complex deposit. Five representative samples were analysed using advanced methods including XRD with Rietveld refinement, SEM-based mineral liberation analysis, and Bond Work Index testing. The ore’s unique association of coarse liberated and finely disseminated iron oxides, especially the coexistence of hematite and magnetite without clear textural replacement, posed distinctive challenges for mineral separation. A key contribution of the study is the identification of an optimal liberation size below 75  µm, uncommon among BIF-related ores in Canada, and the demonstration that a pre-concentration stage significantly improves the performance of low-intensity magnetic separation, yielding Fe concentrates with up to 70.15 % Fe and < 2.5 % SiO₂ (magnetitic ore). Moreover, the study quantitatively linked Mn-rich lithologies (rhodonite-bearing layers) to higher grinding energy requirements and deleterious impacts on concentrate quality. Based on these findings, a tailored flowsheet was proposed with bifurcated circuits for magnetite and hematite recovery. The results emphasize the importance of fine-scale process-mineralogy integration for developing viable beneficiation routes in low-grade, complex iron ore systems.