Vale, ABB expand AI, automation across Brazil iron ore

Vale (NYSE: VALE) and ABB (SWX: ABBN) are expanding their partnership to deploy automation and artificial intelligence across the miner’s iron ore processing operations in Brazil. 

The strategic alliance aims to expand the use of automation and Artificial Intelligence (AI) technologies to increase safety, productivity and sustainability in mineral production in Brazil.  

The partnership builds on the companies’ work at Vale’s Conceição II plant, which Vale describes as its first high-tech, AI-enabled venture.  

Conceição II automated more than 7,000 instruments, including sensors and measurement devices and added more than 100 monitoring cameras. 

Data intelligence was also used to manage and optimize more than 400 variables across the iron ore processing workflow, helping anticipate failures and avoid unplanned shutdowns.  

The 11.2 million-tonne-per-year plant reported a 25% increase in productivity since the technologies were implemented in 2024.  

 The plant also reported a 40% increase in premium ore production for direct reduction and a 26% reduction in iron losses to tailings. The technologies reduced the need for manual field interventions, improving worker safety.. 

“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,” Carlos Medeiros, Vale's Vice President of Operations, said. 

 ABB is providing industrial automation, digitalization and integrated information technology and operational technology (IT/OT) solutions under the partnership. 

“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,” Joachim Braun, President of ABB's Process Industries Division, said 

 The companies plan to gradually deploy the technologies at other iron ore plants in Brazil, using Conceição II as a blueprint to improve productivity and energy efficiency and expand digitalization. 

“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,” said Medeiros.