This research explores the beneficiation of low-grade iron ore from Botswana using non-coking coal as a reductant through the process of reduction roasting and subsequent magnetic separation. The increasing global demand for steel, coupled with the depletion of high-grade iron ore deposits, necessitates the exploration of low-grade resources to maintain a stable iron supply. Most iron ore globally is processed through traditional blast furnace methods, which require high-grade ores. However, the exhaustion of these high-grade deposits has driven efforts to upgrade low-grade ores, which present unique challenges due to their higher impurity content and lower iron concentration. This study explores an alternative approach using abundant local resources in Botswana, such as low-grade iron ore and semi-bituminous coal. The iron ore from the Ikongwe Mine presents a significant opportunity for value addition; particularly as high-quality ore deposits are increasingly depleted globally. Given the considerable reserves of semi-bituminous coal in Botswana, this research investigates the feasibility of employing locally sourced reductants to enhance the iron content of locally low-grade ores, making them suitable for industrial applications. The experimental methodology involved mineralogical and chemical characterisation of both the ore and coal samples, followed by reduction roasting in a muffle furnace at varying temperatures (700°C, 800°C, and 900°C), residence times, and coal-to-ore ratios. Taguchi experimental design was employed to optimise process parameters, including roasting time and coal dosage, ensuring efficient conversion of hematite to magnetite, which was subsequently separated using low-intensity magnetic separation. The key findings show a significant improvement in iron content, increasing from 56% to over 68%, with the optimal roasting temperature identified at 800°C, and a coal dosage of 0.5%. This indicates the potential of Botswana’s non-coking coal to serve as a reductant for iron ore beneficiation, achieving recovery rates and Fe grades comparable to established processes. Thermodynamic and kinetic analyses further validate the feasibility of this approach, with activation energies calculated at 159.1 to 160.6 kJ/mol aligning with industry benchmarks. The reaction mechanisms during reduction roasting are detailed through a gas-solid reaction model, highlighting the crucial role of carbon monoxide as a reducing agent and the importance of maintaining optimal temperature and coal ratios for efficient hematite to magnetite conversion. This study concludes that the integration of locally sourced non-coking coal for iron ore beneficiation is not only technically viable but also holds promise for economic diversification in Botswana, reducing the nation's dependency on iron and steel imports.