1. Mining of Iron Ore

Iron ore is extracted from open-pit or underground mines. Common types include:

• Hematite (Fe₂O₃)
• Magnetite (Fe₃O₄)
• Limonite
• Siderite

2. Beneficiation Process (Ore Preparation)

Beneficiation improves the ore's iron content and removes impurities (gangue materials like silica, alumina).

• Crushing and Grinding – Reduces ore to fine particles.
• Screening – Separates particles based on size.
• Magnetic Separation – Uses magnetic properties to extract iron-rich particles.
• Gravity Separation – Uses water or air flow to separate heavier particles.
• Froth Flotation – Removes impurities using chemical reagents (if required).

3. Concentration and Pelletizing

Fine ore is concentrated and sometimes agglomerated into pellets or sinter for easier use in blast furnaces.

4. Smelting (Refining)

Converts iron ore into metallic iron (pig iron or steel) via:

• Blast Furnace Process – Uses coke, limestone, and ore to produce molten iron and slag.
• Direct Reduced Iron (DRI) – Produces sponge iron using natural gas or coal.

5. Steelmaking (Optional Final Step)

Pig iron is converted to steel by removing carbon and other impurities in:

• Basic Oxygen Furnace (BOF)
• Electric Arc Furnace (EAF)