Brazilian mining major Vale and Swiss technology group ABB have sealed a strategic partnership to speed up digital transformation across Brazilian iron ore processing sites, according to Mining.com. 

The cooperation covers large-scale rollout of automation, artificial intelligence (AI), electrification and integrated IT/OT solutions, targeting improved site safety, higher productivity, better energy efficiency and enhanced environmental sustainability for mineral output.

The expanded initiative builds on successful modernization work completed at Vale's Conceicao II processing plant in Minas Gerais, the miner's first AI-powered high-tech facility with an annual capacity of 11.2 million tonnes.

As part of the pilot deployment, more than 7,000 sensors and measuring instruments were automated, alongside over 100 monitoring cameras. Data analytics optimized more than 400 production variables, enabling early fault prediction and avoidance of unplanned equipment outages.

Digital technologies officially deployed at the plant starting in 2024 have yielded tangible operational improvements across key metrics. The facility's overall productivity has climbed 25%, while output of high-quality premium ore for direct reduction has risen by 40%. Meanwhile, iron resource losses to tailings have been cut by 26%, and the sharp reduction of manual on-site operations has effectively lowered occupational safety risks for frontline workers.

Vale's Vice-President of Operations Carlos Medeiros said that the Model plant project has proven that AI can boost workforce safety, product quality and operational efficiency. The company noted its data-led operating model bolsters overall market competitiveness.

Joachim Braun, president of ABB's Process Industries Division, stated that lessons from Conceicao II will form a unified automation and digitalization blueprint, to be gradually replicated across Vale's other Brazilian iron ore processing assets.