Vale and ABB have signed a strategic alliance aimed at accelerating mining digital transformation across Vale’s iron ore operations in Brazil. The agreement follows the inauguration of the Conceição II Model Plant in Itabira, Minas Gerais, one of the most advanced iron ore processing facilities in the industry. The Vale ABB partnership will now serve as a foundation for replicating the plant’s technological solutions across other operations.
Strategic Alliance to Scale Iron Ore Digitalisation
The alliance builds on a long-standing collaboration between the two companies. ABB served as consultant, systems integrator and technology provider during the development of the Conceição II plant, contributing to advanced industrial automation, iron ore digitalisation and integrated IT/OT solutions. The focus was on optimising operations while improving safety and sustainability.
Vale plans to gradually expand the application of mining automation and artificial intelligence mining technologies to its broader portfolio of iron ore processing plants. The goal is to increase operational safety, boost performance and raise production quality. Mining digital transformation sits at the heart of this strategy, which Vale has branded as its Mining of the Future initiative.
Conceição II Model Plant Results
Inaugurated in June 2025, the Conceição II Model Plant has an annual capacity of 11.2 Mt. The facility features more than 100 monitoring cameras and the automation of more than 7,000 instruments, including advanced sensors and measurement devices. Data intelligence systems manage and optimise more than 400 variables across all stages of ore processing. Operating flows were also redesigned to anticipate failures and prevent unplanned shutdowns.
Since implementation in 2024, the plant has delivered strong results. Productivity rose by 25 per cent, premium ore production for direct reduction grew by 40 per cent, and iron losses in tailings fell by 26 per cent. The new setup also reduced the need for manual interventions, contributing to a safer working environment. These outcomes highlight how mining digital transformation can deliver measurable gains in both efficiency and worker protection.
Expanding Mining Automation Across Vale Operations
With the Conceição II plant now serving as a blueprint, the Vale ABB partnership aims to deploy a consistent approach to automation, electrification and iron ore digitalisation across multiple sites.
Carlos Medeiros, Vale’s Vice President of Operations, said the Model Plant Project demonstrated that technologies such as artificial intelligence mining improve employee safety while increasing productivity, operational efficiency and quality. He added that the company would take these learnings to other Vale operations, improving process predictability, mineral resource use and reducing worker exposure to risky activities.
Joachim Braun, President of ABB’s Process Industries Division, described the new agreement as an important milestone in the partnership. He said the companies were creating a framework to scale mining automation and digitalisation consistently, building on the success achieved at Conceição II.
The strategic alliance reinforces both companies’ commitment to mining digital transformation as a driver of safer, more sustainable and data-driven operations across Brazil’s iron ore sector.