Vale and ABB have entered into a strategic partnership aimed at developing automation, digitalisation and integrated IT\/OT technology solutions for iron ore processing operations in Brazil. <\/p>\n
The agreement follows their work together at Vale’s Concei\u00e7\u00e3o II Model Plant in Itabira, Minas Gerais, which is the company’s first high-tech and AI-enabled iron ore facility. <\/p>\n
The companies intend to replicate the technology systems implemented at the Itabira site across multiple Vale iron ore plants in Brazil. <\/p>\n
These solutions are designed to improve safety, enhance productivity and support sustainability in mineral production. <\/p>\n
The Concei\u00e7\u00e3o II Model Plant, inaugurated in June 2026, is a central project within Vale’s Mining of the Future strategy. <\/p>\n
ABB served as consultant, technology provider and systems integrator, focusing on advanced automation, digitalisation and IT\/OT integration. <\/p>\n
As part of the upgrade, more than 100 monitoring cameras and over 7,000 automated instruments, including measurement devices and sensors, were installed at the 11.2 million tonnes per year facility. <\/p>\n
Analytical data tools are applied to oversee, regulate and enhance more than 400 variables throughout the entire ore processing sequence. <\/p>\n
The design of operational processes was also reassessed in order to predict potential faults and minimise unexpected stoppages. <\/p>\n
Vale operations vice-president Carlos Medeiros said: “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. <\/p>\n
“Now, we are going to take this learning to other Vale operations, increasing the predictability of processes, improving the use of mineral resources and reducing people’s exposure to risky activities.” <\/p>\n
Vale reports that since implementing these digital solutions at Concei\u00e7\u00e3o II, the site has seen productivity rise by 25%, production of premium ore for direct reduction increase by 40%, and iron losses in tailings fall by 26%. <\/p>\n
The automation has also reduced the need for manual interventions, which contributes to safer operations. <\/p>\n
ABB’s Automation division focuses on automating, electrifying and digitalising industrial operations across various sectors, including mineral production. <\/p>\n
In June 2026, ABB launched Grinding Connect<\/a>, a digital service suite for mining operators using gearless mill drive (GMD) systems. <\/p>\n