The municipality of Itabira, about 100 kilometres from Belo Horizonte (MG), where Vale was founded 84 years ago, has been chosen to host the company’s first high-tech iron ore plant, marking the beginning of a new operating model driven by data intelligence.
The Conceição 2 plant has been modernised to integrate processes using Artificial Intelligence (AI), expand automation, and reduce people’s exposure to hazardous activities. With a capacity of 11.2 Mt per year, the unit will serve as a benchmark for expanding the model to other company operations.
“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. This initiative positions Vale at the forefront of the most modern and innovative iron ore processing plants in the world. The Model Plant program integrates technologies and robust process governance, creating a safer, more predictable, and more efficient environment, with highly skilled people,” says Carlos Medeiros, Vale’s Vice President of Operations.
The initiative is part of Vale’s mining strategy for the future, based on more connected and sustainable operations, with technology and innovation as drivers of safety, efficiency, and value generation. The implementation of the Model Plant in Itabira took 1.5 years and included 51 solutions to eliminate bottlenecks and improve operations.
More than 100 monitoring cameras were installed across the plant complex, along with the automation of approximately 7,300 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 modernisation of the new plant enables a more integrated, highly monitored, and safer operation. The system includes an artificial intelligence layer that supervises hundreds of variables and performs real-time adjustments to the production process according to the characteristics of the ore and the product,” adds Medeiros.
In less than two years of the pilot project, the plant increased productivity by 25%, reaching its planned capacity. In 2024, production was 9 Mt, and for this year the plant is already capable of producing 11.2 Mt.
There was also progress in the plant’s product mix. The share of direct reduction pellet feed – a premium and strategic product for steel decarbonisation – increased by 40%. In addition, mineral recovery was optimised, improving resource utilisation and operational efficiency.
Quality gains include the application of online ore grade analysis technology during processing, enabling immediate adjustments. This technology allows instant correction of the mineral processing route, ensuring better use of the iron contained in the material and reducing waste generation. In 2026, the average iron content in waste was reduced by 26%.
Another important advancement is improved employee safety in the operational environment, with fewer manual interventions in the industrial plant. The implementation of new technologies includes remote operation solutions, such as robotic arms, and the automation of electrical and mechanical equipment, such as motors and valves, enabling the plant to be operated remotely from control rooms.
When access to facilities is required, real-time images and data support more precise planning of activities.
“The plant has reached a new level of digital maturity, with 100% of critical operational decisions supported by expert systems. This advancement combines innovation, technology, and technical expertise to increase efficiency, reduce impacts, and enhance predictability, with a focus on people,” says Rafael Bittar, Vale’s Technical Vice President.
The model also improves efficiency in the use of natural resources by increasing water reuse rates. Currently, 92% of the water used in the Conceição 2 plant is recirculated. After filtration of the ore and waste – the final stages of processing – the water returns to the operation.
“The Model Plant embodies Vale’s vision of the future of mining and is a decisive step toward safer, more sustainable, and more competitive mining, prepared for the challenges of the coming decades,” explains Bittar.
For the implementation of the Model Plant in Itabira and the expansion of the model to other operational units, Vale relies on a strategic alliance with ABB, a global leader in automation and electrification.
“The Model Plant Program demonstrates extraordinary vision by combining cutting-edge technology with safety and operational excellence. The initiative positions Vale at the forefront of global mining. We are proud to contribute our expertise in automation, electrification, and digitalisation technologies to the sector,” says Fausto Almeida, ABB’s Mining Director for South America.
One of the program’s differentiators is the creation of a partner ecosystem focused on integrating technologies already adopted by Vale.
This strategy optimises existing investments, reduces the need for new capital, and accelerates results. In this context, ABB acts as a technology integrator, ensuring interoperability between systems and suppliers.
The Model Plant Program connects operations, technology, and people development for the future of mining. All 122 operators, instrument technicians, and leaders at the Conceição 2 plant were trained to operate under the new model, totalling more than 2,800 hours of training.
Digital transformation expands operational capabilities, with professionals better prepared to work in integrated environments, analyse data, and support real-time decision-making. This is the case of Ivo Castro, 43, an Equipment and Plant Installations Operator at Vale for 17 years.
“Technology has added a lot. I didn’t have much knowledge of digital systems, and I improved my skills during the training. Today I work with more safety, information, and agility. Before, I was constantly in the field, checking installations and performing manual operations. Now I can monitor areas on my phone, in the palm of my hand. I only go to the field when needed,” says Castro.
Vale maintains ongoing training programs to prepare employees for industry challenges. These include immersive training with simulators and virtual reality that replicate real operating conditions, enabling safe learning aligned with new digital demands.
The initiative reinforces the company’s commitment to turning technological advancement into opportunities for development, growth, and upskilling for its employees.
The post Vale opens benchmark AI-enabled iron ore processing plant in Itabira appeared first on International Mining.