Vale, ABB expand automation partnership across Brazil iron ore plants

Vale and ABB have formalized a strategic partnership to deploy automation, digitalization and integrated IT/OT systems across multiple iron ore processing facilities in Brazil, building on successful results at Vale's Conceição II Model Plant in Itabira, Minas Gerais.

The expansion follows proven performance at Conceição II, Vale's first high-tech, AI-enabled iron ore operation, which opened in June 2026 as a cornerstone of the company's Mining of the Future strategy. ABB served as consultant, technology provider and systems integrator for that facility, according to details first reported by Mining Technology.

Measurable gains at the pilot site

The 11.2 million tonnes per year Conceição II facility demonstrates the business case for scaled deployment. Since implementing ABB's digital solutions, the site has recorded productivity increases of 25%, production of premium ore for direct reduction up 40%, and iron losses in tailings down 26%.

The technology infrastructure includes more than 100 monitoring cameras and over 7,000 automated instruments—measurement devices and sensors that feed analytical tools tracking more than 400 variables across the ore processing sequence. Operational processes were redesigned to predict potential faults and minimize unplanned downtime.

"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," said Carlos Medeiros, Vale's operations vice-president. "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."

Why it matters

Iron ore producers face mounting pressure to improve safety records, extract more value from existing deposits, and reduce environmental impact—all while maintaining output. Vale's decision to standardize automation across its Brazilian operations signals confidence that the technology delivers returns substantial enough to justify capital deployment at scale. The partnership also reflects how industrial AI applications are moving from pilot projects to production rollouts in heavy industry.

Automation reduces manual intervention

A key safety benefit comes from reducing the need for manual interventions in processing operations. The automated systems handle routine monitoring and adjustments that previously required workers to be present in potentially hazardous areas of the plant.

ABB's Automation division specializes in automating, electrifying and digitalizing industrial operations across sectors including mineral production. The company launched Grinding Connect, a digital service suite for mining operators using gearless mill drive systems, in June 2026.

The partnership positions both companies to replicate the Conceição II model across Vale's portfolio, applying lessons learned from the initial deployment to accelerate implementation timelines and optimize system configurations for different site conditions.

Details of the partnership were first reported by Mining Technology.