Fusion-Based Analytical Approaches to Iron Grade Determination in Complex Oxide Ore Systems

Magnetite-rich iron ores present analytical challenges due to mineralogical complexity, including titanium–vanadium (Ti-V) substitution within magnetite and variable silicate gangue contributions. Reliable iron (Fe) quantification in such systems is essential for accurate resource evaluation and beneficiation planning, particularly in layered intrusion-hosted deposits. This study compares fusion-based inductively coupled plasma optical emission spectroscopy (ICP-OES) and fused-bead X-ray fluorescence (XRF) methods for the determination of Fe and associated major elements in magnetite-bearing Fe ores from the Bushveld Igneous Complex, South Africa. Four representative ore samples and certified reference materials were analysed using both techniques. Comparative statistical parameters like the t-test and F-test exhibit no significant differences in either precision and mean concentration between fused-based ICP-OES and fused-based XRF methods for the determination of Fe and other elements. The results indicate that, despite the existence of titanomagnetite and lithologies that are rich in silicates, both fusion-based methods provide consistent and reliable bulk chemical analysis datasets. While both approaches show suitability for routine chemical analysis, fusion-based ICP-OES offers a practical advantage in terms of throughput and operational efficiency. This work emphasises the importance of matching analytical methods with mineral ore characterisation in order to ensure reliable Fe grade determination in complicated oxide deposits.