Vale and ABB have signed a strategic alliance to expand the use of automation, artificial intelligence (AI) and digital technologies across Vale’s iron ore operations in Brazil. The partnership aims to improve safety, productivity, operational efficiency and sustainability while supporting more effective use of mineral resources.
The agreement builds on the success of Vale’s Conceição II Model Plant in Itabira, which was inaugurated in June and is a key project under the company’s Mining of the Future strategy. The plant will serve as a technology reference for the wider Vale network, with solutions developed at the facility expected to be progressively introduced at other iron
ABB supported Vale as a consultant, systems integrator and technology provider during the development of the Conceição II Model Plant. The companies worked together on automation, digitalisation and integrated IT/OT solutions, with a focus on improving plant performance, safety and reliability.
The 11.2-million-tonne-per-year facility is equipped with more than 100 monitoring cameras and more than 7,000 automated instruments, including advanced measurement devices and sensors. Data intelligence is used to monitor, manage and optimise more than 400 variables across the ore processing operation.
Operational processes have also been redesigned to identify potential failures earlier and reduce the risk of unplanned shutdowns. The increased use of automation has reduced the need for manual intervention in the field, helping limit employee exposure to potentially hazardous activities. Since implementation began in 2024, the Conceição II Model Plant has recorded a 25% increase in productivity, a 40% increase in premium ore production for direct reduction and a 26% reduction in iron losses in tailings.
Carlos Medeiros, Vice President of Operations at Vale, said the project has demonstrated how technologies such as AI can improve employee safety while increasing productivity, operational efficiency and product quality. He said Vale will use the experience gained at Conceição II to expand digital solutions to other operations, improve process predictability, optimise mineral resources and reduce employee exposure to risky activities.
Joachim Braun, President of ABB’s Process Industries Division, said the new agreement strengthens the companies’ long-standing partnership and creates a framework for applying automation, electrification and digitalisation solutions across multiple Vale operations. The alliance is expected to support Vale’s efforts to build safer, more efficient and data-driven mining operations. It will also enable the company to standardise proven technologies while adapting them to the requirements of individual processing plants.
ABB provides electrification and automation technologies for industries worldwide. With more than 140 years of history and around 110,000 employees, the company develops solutions focused on improving industrial efficiency, productivity and resource use. Its Automation business serves process, hybrid and maritime industries through automation, electrification and digital technologies.
