Under the agreement formalized on August 11, the technological solutions implemented at Vale’s Conceição II Model Plant in Itabira, in the state of Minas Gerais, are planned to be gradually transferred to the company’s other iron ore processing plants.
The cooperation aims to increase operational safety, improve production performance and enhance product quality, while the model developed at Conceição II will serve as a reference for the technological transformation of Vale’s other facilities.
Brucutu plant to become operational in early 2027
As part of the project, which represents a new phase of Vale’s “Mining of the Future” strategy, the company aims to further integrate advanced automation, digitalization and artificial intelligence technologies into its production processes.
The implementation of the technologies has begun at Vale’s Brucutu iron ore processing plant in São Gonçalo do Rio Abaixo, with the facility expected to become operational with the new systems in early 2027. New applications are also planned to be implemented at other Vale facilities in Minas Gerais and Pará.
Vale Executive Vice President for Operations Carlos Medeiros said the Model Plant Project demonstrates that new technologies such as artificial intelligence can improve productivity, operational efficiency and quality in mining while increasing worker safety.
Medeiros stated that by transferring the experience gained at Conceição II to other Vale operations, the company aims to increase process predictability, use mineral resources more efficiently and reduce workers’ exposure to high-risk activities.
More than 400 variables monitored in real time
The Model Plant program brings different technologies together on a single operational platform, enabling hundreds of process variables to be continuously monitored in real time. ABB is acting as the system integrator in the project, ensuring interoperability between different technologies and suppliers.
ABB Process Industries Division President Joachim Braun said that following the results achieved at Conceição II, the new agreement provides a framework for applying the approach to automation, electrification and digitalization across multiple operations.
Opened in Itabira in June 2026, the Conceição II Model Plant is among the key projects under Vale’s “Mining of the Future” strategy.
The plant uses thousands of sensors, along with advanced automation systems and artificial intelligence tools. The systems monitor more than 400 variables in real time across all stages of the iron ore processing process and can make automatic adjustments to optimize production.
Efficiency increased by 25%
According to results announced by Vale, efficiency at Conceição II has increased by 25% since the technologies began to be implemented in 2024.
During the same period, production of premium iron ore for direct reduction processes increased by 40%, while iron losses in tailings were reduced by 26%.
The new system has also reduced the need for manual intervention at the site, contributing to lower employee exposure to operational risks.
As part of the transition to the new operating model, Vale trained all operators, instrumentation technicians and managers at the Conceição II plant. The company also continues to prepare its employees for the digital transformation of the mining industry through simulators that replicate real operating conditions, virtual reality applications and comprehensive training programs.
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