<p>Given the steady increase in global steel demand and the growing scarcity of readily processible high-grade iron ore, the effective exploitation of refractory iron ores has emerged as a crucial strategy to mitigate resource constraints. This study proposes an innovative method for efficiently extracting iron and removing impurities from refractory limonite ore through a preconcentration-suspension magnetization roasting-magnetic separation process. The optimal suspension magnetization roasting test conditions are a roasting temperature of 500°C, a CO concentration of 45%, a feed rate of 140&#xa0;kg/h, and a total gas flow of 16.7 m³/h. Through stable operation of pilot-scale tests, a high-quality iron concentrate was obtained with an Fe grade of 67.47%, a recovery rate of 97.05%, a yield of 80.39%, and a SiO₂ content of 3.54%. The product properties were analyzed using XRD, iron phase analysis, and SEM-EDS. During the suspension magnetization roasting process, limonite is reduced to magnetite, the cracks in the iron ore increase, and the structure becomes loose and porous. These changes facilitate the penetration of reducing gases into the solid matrix, thereby accelerating the reaction rate. Overall, this work offers a novel pathway for the effective processing of refractory limonite ores.</p>