The municipality of Itabira, about 100 kilometres from Belo Horizonte (MG), the place Vale was based 84 years in the past, has been chosen to host the corporate’s first high-tech iron ore plant, marking the start of a brand new working mannequin pushed by knowledge intelligence.
The Conceição 2 plant has been modernised to combine processes utilizing Synthetic Intelligence (AI), develop automation, and cut back folks’s publicity to hazardous actions. With a capability of 11.2 Mt per 12 months, the unit will function a benchmark for increasing the mannequin to different firm operations.
“The mannequin plant is greater than a mission: it represents a brand new approach of working, primarily based on the applying of superior applied sciences that redefine requirements of effectivity, sustainability, and competitiveness in mining. This initiative positions Vale on the forefront of essentially the most fashionable and modern iron ore processing vegetation on this planet. The Mannequin Plant program integrates applied sciences and sturdy course of governance, making a safer, extra predictable, and extra environment friendly setting, with extremely expert folks,” says Carlos Medeiros, Vale’s Vice President of Operations.
The initiative is a part of Vale’s mining technique for the longer term, primarily based on extra linked and sustainable operations, with know-how and innovation as drivers of security, effectivity, and worth technology. The implementation of the Mannequin Plant in Itabira took 1.5 years and included 51 options to remove bottlenecks and enhance operations.
Greater than 100 monitoring cameras had been put in throughout the plant advanced, together with the automation of roughly 7,300 devices, together with new superior measurement gadgets and sensors. Knowledge intelligence can also be used to manage, handle, and optimize greater than 400 variables throughout all phases of the ore processing workflow. Working flows had been additionally reviewed to anticipate failures and keep away from unplanned shutdowns.
“The modernisation of the brand new plant allows a extra built-in, extremely monitored, and safer operation. The system contains a man-made intelligence layer that supervises a whole bunch of variables and performs real-time changes to the manufacturing course of in response to the traits of the ore and the product,” provides Medeiros.
In lower than two years of the pilot mission, the plant elevated productiveness by 25%, reaching its deliberate capability. In 2024, manufacturing was 9 Mt, and for this 12 months the plant is already able to producing 11.2 Mt.
There was additionally progress within the plant’s product combine. The share of direct discount pellet feed – a premium and strategic product for metal decarbonisation – elevated by 40%. As well as, mineral restoration was optimised, bettering useful resource utilisation and operational effectivity.
High quality positive factors embrace the applying of on-line ore grade evaluation know-how throughout processing, enabling fast changes. This know-how permits instantaneous correction of the mineral processing route, guaranteeing higher use of the iron contained within the materials and lowering waste technology. In 2026, the typical iron content material in waste was diminished by 26%.
One other essential development is improved worker security within the operational setting, with fewer guide interventions within the industrial plant. The implementation of latest applied sciences contains distant operation options, corresponding to robotic arms, and the automation {of electrical} and mechanical gear, corresponding to motors and valves, enabling the plant to be operated remotely from management rooms.
When entry to amenities is required, real-time pictures and knowledge assist extra exact planning of actions.
“The plant has reached a brand new stage of digital maturity, with 100% of crucial operational choices supported by professional techniques. This development combines innovation, know-how, and technical experience to extend effectivity, cut back impacts, and improve predictability, with a give attention to folks,” says Rafael Bittar, Vale’s Technical Vice President.
The mannequin additionally improves effectivity in using pure assets by growing water reuse charges. At present, 92% of the water used within the Conceição 2 plant is recirculated. After filtration of the ore and waste – the ultimate phases of processing – the water returns to the operation.
“The Mannequin Plant embodies Vale’s imaginative and prescient of the way forward for mining and is a decisive step towards safer, extra sustainable, and extra aggressive mining, ready for the challenges of the approaching many years,” explains Bittar.
For the implementation of the Mannequin Plant in Itabira and the growth of the mannequin to different operational models, Vale depends on a strategic alliance with ABB, a worldwide chief in automation and electrification.
“The Mannequin Plant Program demonstrates extraordinary imaginative and prescient by combining cutting-edge know-how with security and operational excellence. The initiative positions Vale on the forefront of worldwide mining. We’re proud to contribute our experience in automation, electrification, and digitalisation applied sciences to the sector,” says Fausto Almeida, ABB’s Mining Director for South America.
One of many program’s differentiators is the creation of a associate ecosystem targeted on integrating applied sciences already adopted by Vale.
This technique optimises present investments, reduces the necessity for brand new capital, and accelerates outcomes. On this context, ABB acts as a know-how integrator, guaranteeing interoperability between techniques and suppliers.
The Mannequin Plant Program connects operations, know-how, and folks growth for the way forward for mining. All 122 operators, instrument technicians, and leaders on the Conceição 2 plant had been educated to function beneath the brand new mannequin, totalling greater than 2,800 hours of coaching.
Digital transformation expands operational capabilities, with professionals higher ready to work in built-in environments, analyse knowledge, and assist real-time decision-making. That is the case of Ivo Castro, 43, an Gear and Plant Installations Operator at Vale for 17 years.
“Expertise has added lots. I didn’t have a lot data of digital techniques, and I improved my abilities in the course of the coaching. At the moment I work with extra security, data, and agility. Earlier than, I used to be continually within the area, checking installations and performing guide operations. Now I can monitor areas on my telephone, within the palm of my hand. I solely go to the sphere when wanted,” says Castro.
Vale maintains ongoing coaching applications to organize workers for trade challenges. These embrace immersive coaching with simulators and digital actuality that replicate actual working circumstances, enabling secure studying aligned with new digital calls for.
The initiative reinforces the corporate’s dedication to turning technological development into alternatives for growth, development, and upskilling for its workers.
