Vale scales AI automation to Brazil iron ore plants after 25% productivity gain

Vale and ABB are expanding their automation and artificial intelligence partnership across the Brazilian miner's iron ore processing facilities, following results at a pilot plant that demonstrated substantial productivity and safety improvements.

The strategic alliance will deploy industrial automation, digitalization, and integrated IT/OT solutions to additional operations in Brazil, using Vale's Conceição II plant as the implementation template, according to details first reported by Mining.com.

Pilot plant delivers measurable results

The 11.2 million-tonne-per-year Conceição II facility, which Vale describes as its first high-tech, AI-enabled operation, automated more than 7,000 instruments including sensors and measurement devices. The plant added over 100 monitoring cameras and deployed data intelligence systems to manage and optimize more than 400 variables across the iron ore processing workflow.

Since implementing these technologies in 2024, the plant reported a 25% increase in productivity. Premium ore production for direct reduction jumped 40%, while iron losses to tailings dropped 26%. The automation reduced manual field interventions, improving worker safety conditions.

"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 vice president of operations.

Why it matters

The expansion represents a significant validation of AI and automation in heavy industrial mining operations, where productivity gains directly impact global steel supply chains. Vale's willingness to scale the technology across multiple facilities signals confidence that the improvements at Conceição II can be replicated systematically. For mining operations worldwide facing pressure to improve both safety records and environmental performance while maintaining output, the quantified results provide a concrete business case for similar investments.

Framework for broader deployment

ABB is providing the industrial automation backbone for the expansion, building on the Conceição II success to create a consistent deployment approach across Vale's operations.

"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," said Joachim Braun, president of ABB's Process Industries Division.

The companies plan gradual deployment at other iron ore plants in Brazil, focusing on productivity improvements, energy efficiency gains, and expanded digitalization. The data intelligence systems help anticipate equipment failures and avoid unplanned shutdowns, addressing a persistent challenge in continuous processing operations.

Medeiros emphasized the strategic importance of the initiative: "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."

The partnership details were first reported by Mining.com.