Vale, ABB expand AI, automation across Brazil iron ore

Vale and ABB are teaming up to implement automation and artificial intelligence across the Brazilian iron ore mining company's processing operations. The aim is to boost safety, productivity, and sustainability in the mining sector in Brazil. The collaboration builds upon Vale's first AI-enabled venture, the Conceição II plant, where over 7,000 instruments have been automated and more than 100 cameras installed for monitoring.

The 11.2 million-tonne-per-year plant has seen a 25% productivity increase since the technologies were introduced in 2024. These technologies have also led to a 40% boost in premium ore production for direct reduction and a 26% decrease in iron losses to tailings. The deployment of AI and automation has led to reduced manual field interventions, thereby enhancing worker safety.

Carlos Medeiros, Vale's Vice President of Operations, stated, "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." ABB, on the other hand, is contributing industrial automation, digitalization, and integrated information technology and operational technology solutions under the partnership.

Joachim Braun, President of ABB's Process Industries Division, added, "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." The companies plan to gradually roll out these technologies to other iron ore plants in Brazil, drawing from Conceição II as a blueprint to enhance productivity, energy efficiency, and digitalization.

Medeiros concluded, "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."