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Crushing and screening is typically the first step of iron ore beneficiation processes. In most ores, including iron ore, valuable minerals are usually intergrown with gangue minerals, so the minerals need to be separated in order to be liberated. This screening is an essential step prior to their separation into ore product and waste rock.

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Beneficiation upgrading tests (prior to leaching) established that scrubbing to reduce the size of (de-agglomerate) the ore particles, followed by screening out material larger than 0.25 mm, could potentially provide a 20 percent upgrade of the limonite and transition HPAL feed material, with 90 percent nickel recovery and 19 percent mass rejection.

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During the last ten years great strides have been made, on the Mesabi range, in the practice of beneficiating low grade iron ore material. By beneficiation is meant all methods of removing impurities, and raising the iron content to a point where it can be sold in open market, the principal impurities being silica and moisture.

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Iron ore is normally beneficiated utilizing the principles applied in separation of the materials by the gravity, floatation, and magnetic methods. Enrichment of ores utilizing the gravity concentration method is one of the oldest and most economic techniques.