Research progress and application potential of super iron concentrate

Super iron concentrate, a high-value-added mineral product derived from the deep processing of conventional iron concentrates through integrated physical and chemical purification technologies, exhibits ultra-low impurity characteristics that meet stringent requirements for ultra-pure iron-based materials in high-end manufacturing. Accelerated by global industrial upgrading and technological innovation, super iron concentrate has emerged as a strategic raw material with surging demand. This paper systematically integrates domestic research achievements since 2000 through bibliometric analysis and experimental validation, focusing on three critical aspects: ① comparative evaluation of “single separation processes” （magnetic separation/gravity separation） versus “combined separation processes” （magnetic-flotation/magnetic-gravity-flotation） reveals the technical superiority of multi-stage purification in enhancing mineral liberation degree and achieving deep impurity removal. ② Mechanism analysis of cationic and anionic collector adsorption in reverse flotation demonstrates cationic reagents’ superior interfacial reactivity for selective quartz/silicate separation without requiring high-valence ion activation. ③ Industry-specific impurity thresholds and impurity-induced performance degradation mechanisms are quantitatively established. Key findings highlight that the magnetic-flotation hybrid process, particularly effective for finely disseminated iron ores, dominates industrial applications. Cationic reverse flotation systems achieve aluminosilicate rejection through electrostatic adsorption mechanisms. While super iron concentrate enables breakthroughs in advanced applications like magnetic materials, powder metallurgy & clean steel, its large-scale deployment faces supply chain risks due to China’s limited high-grade magnetite reserves and import dependency. This paper establishes a theoretical framework encompassing “impurity control-interface modulation-industrial upgrading” for super iron concentrate production, while proposing frontier directions including microwave-assisted liberation and bio-flotation technologies. The outcomes provide critical technical references for iron resource valorization and strategic mineral security enhancement.