The technology has already been trialled at the Conceição II plant, which has an annual capacity of 11.2 million tonnes

Brazilian mining company Vale and Swiss technology group ABB have signed a strategic partnership agreement to accelerate digital transformation, according to Mining.com.

The project involves the large-scale implementation of automation systems, artificial intelligence (AI), electrification and integrated IT/OT solutions at iron ore processing plants in Brazil. The main aim of the collaboration is to improve worker safety, increase productivity, energy efficiency and the environmental sustainability of production.

The new initiative builds on the successful modernisation of the Vale Conceição II plant in the state of Minas Gerais, which has an annual capacity of 11.2 million tonnes. This facility became the company’s first high-tech plant to utilise artificial intelligence. As part of the pilot project, over 7,000 measuring instruments and sensors were automated, more than 100 surveillance cameras were installed, and data analytics were utilised to optimise over 400 production process variables. This made it possible to predict potential faults and avoid unplanned equipment downtime.

The introduction of digital technologies in 2024 proved highly effective:

1. The plant’s productivity increased by 25%.

2. Output of high-quality, premium-grade ore for direct reduction rose by 40%.

3. Iron losses in tailings ponds were reduced by 26%.

4. The need for manual intervention was minimised, significantly reducing risks to the health and safety of workers in hazardous areas.

As noted by Vale’s Vice-President of Operations, Carlos Medeiros, the project has demonstrated that artificial intelligence enhances staff safety, product quality and operational efficiency. The company emphasises that its data-driven approach strengthens its competitiveness.

For his part, Joachim Braun, President of ABB’s Process Industries division, emphasised that the experience gained from Conceição II will form the basis for creating a unified standard for automation and digitalisation, which will be gradually rolled out to Vale’s other iron ore mines in Brazil.

Vale has published its report for the second quarter of 2026. Iron ore production reached 84.3 million tonnes (including 76 million tonnes of ore mined in-house), which is 0.8% (0.7 million tonnes) higher than in the same period last year. At the same time, pellet production for the reporting period fell by 7% year-on-year – to 7.3 million tonnes.