Brazilian miner Vale has entered into a strategic alliance with Swiss electrification and automation technology company ABB to expand the use of automation and AI technologies for improved safety, productivity and sustainability in mineral production.

The partnership follows Vale's inauguration of one of the most advanced iron-ore processing plants in the industry, the Conceição II Model Plant in Itabira, Minas Gerais, which was inaugurated in June.

The ABB and Vale-developed model plant is serving as a reference for the technological evolution of other Vale units, with the mining company planning to expand the application of automation, AI and digitalization significantly.

"The partners will gradually replicate the technological solutions implemented at the Itabira plant in other iron-ore processing plants. Vale’s aim is to increase the safety of operations, improve operational performance and raise the quality of production," Vale elaborates.

The Conceição II Model Plant represents one of the main projects of Vale's Mining of the Future strategy.

ABB acted as consultant, systems integrator and technology provider in the partnership, cooperating on the development, validation, interoperability and scalability of advanced industrial automation, digitalization and integrated information technology and operations technology solutions, which all aimed to optimise operations.

More than 100 monitoring cameras were installed across the 11.2-million tonnes a year complex, along with the automation of more than 7 000 instruments, including new advanced measurement devices and sensors.

Data intelligence is also used to control, manage and optimize more than 400 variables across all stages of the ore processing workflow. Operating flows were also reviewed to anticipate failures and avoid unplanned shutdowns.

The results from Conceição II demonstrated the potential of digital transformation in mining, Vale says.

Since its implementation in 2024, the plant has recorded a 25% increase in productivity, a 40% growth in the production of premium ore for direct reduction, and a 26% reduction in iron losses in the tailings. The new configuration also reduced the need for manual interventions in the field, contributing to a safer operation for employees.

Now, with the unit serving as a blueprint for expanding the model to other company operations, Vale and ABB have signed a strategic alliance to bring forward their shared vision of driving productivity, safety, energy efficiency, digitalization and sustainability across operations.

“The Model Plant project has shown that new technologies, such as artificial intelligence, improve employee safety and increase productivity, operational efficiency and quality in mining,” says Vale operations VP Carlos Medeiros. 

“Now, we are going to take this learning to other Vale operations, increasing the predictability of processes, improving the use of mineral resources and reducing people's exposure to risky activities. The initiative reinforces our new way of operating, which is increasingly safe, sustainable and data-driven, strengthening our competitiveness and preparing us for the challenges of the future.”

In turn, ABB process industries division president Joachim Braun says this new agreement with Vale represents an important milestone in the partnership between the companies. “Building on the success achieved in Conceição II, we are creating a framework to deploy a consistent approach to automation, electrification and digitalization across multiple operations.”