How AI Boosted Vale’s Iron Ore Production in Brazil

AI has helped bring a 25% boost in productivity to Vale’s Model Plant in Itabira, Brazil, where iron ore is extracted and processed.

The site’s planned production is growing from 9 million tonnes in 2024 to 11.2 million in 2026.

More than 100 cameras have been installed and around 7,300 instruments are now fully automated at the facility

This site is set to act as a benchmark for expanding the technology to other operations within the company.

Carlos Medeiros, Vale’s Vice President of Operations, says: “The Model Plant is more than a project: it represents a new way of operating, based on the application of advanced technologies that redefine standards of efficiency, sustainability and competitiveness in mining.”

Inside Vale’s Itabira Model Plant

Full automation of Vale’s Model Plant spanned across 18 months and included 51 solutions to remove bottlenecks.

These solutions have also improved operations, increasing the plant’s production capability for 2026.

Prior to full automation, the site produced nine million tonnes of Iron ore and the company says it is now able to produce 11.2 million.

One key factor of the automation technology is a new data intelligence platform, which controls, manages and optimises more than 400 variables. 

It also applied online ore grade analysis technology, which allows for instant correction of the mineral processing route.

The company says that this feature ensures better use of the iron contained in the material and reduces the average iron content in waste by 26%.

Alongside these technological additions, Vale has also seen a rise in product variety at the facility.

The plant’s share of direct reduction pellet feed, a product for steel decarbonisation, was increased by 40% during the two-year pilot project.

Vale and ABB’s alliance

To modernise its Model Plant, Vale formed a strategic alliance with automation and electrification company ABB.

In this partnership, ABB acts as a technology integrator and ensures interoperability between systems and suppliers.

“The Model Plant Program demonstrates extraordinary vision by combining cutting-edge technology with safety and operational excellence,” says Fausto Almeida, ABB’s Mining Director for South America.

Part of the strategy behind Vale’s alliance with ABB is to optimise existing investments and accelerate results.

It also aims to support Vale’s mining strategy for the future, which the company describes as a more connected and sustainable operation with technology driving safety, efficiency and value.