Vale Turns On an AI-Run Plant That Lifts Iron-Ore Output 25%

Brazil · Markets

The world’s second-largest iron-ore miner has switched on its first Vale AI plant, a heavily automated facility in Brazil that has lifted output by 25% and cut waste, and which the company intends to use as a blueprint across its mines.

The automated facility in Itabira is Vale’s first AI-run processing plant. (Photo: Internet reproduction)

Inside the first Vale AI plant

Vale, the Brazilian giant that ranks as the world’s second-largest producer of iron ore, opened its first high-technology processing plant on Wednesday, June 10, and the early numbers are striking. The facility, an upgrade of an existing plant called Conceição 2, raised productivity by 25% during a pilot phase that ran for less than two years. For a heavy, capital-intensive industry where gains are usually measured in low single digits, a quarter more output from the same site is a large step. The plant now produces 11.2 million tonnes of iron ore a year, up from 9 million in 2024.

The location is not incidental. The plant sits in Itabira, the town in the state of Minas Gerais where Vale was founded 84 years ago, giving the launch a symbolic weight as the company’s birthplace becomes the showcase for its digital future. The overhaul cost about R$200 million ($38.8m), modest by mining standards, and turned an ordinary plant into what Vale calls a “model plant,” a template it plans to replicate elsewhere. Much of the work can now be supervised remotely, with trained teams watching over the process from control rooms rather than the plant floor.

How the technology works

At the heart of the upgrade is a layer of artificial intelligence that watches the plant in real time and adjusts it on the fly. The system supervises more than 400 separate variables in the process of turning raw rock into usable iron ore, tweaking the treatment as the characteristics of the incoming material change. To feed it, Vale installed more than 100 cameras and automated around 7,300 instruments, and added sensors that read the iron content of the ore online, as it moves through the plant. That lets operators correct the process immediately rather than discovering problems after the fact.

For a reader outside the industry, the simplest way to picture it is a factory that constantly tunes itself. Rock dug from the ground varies in quality from load to load, and a traditional plant is set up for an average. By measuring each batch and adjusting continuously, the AI squeezes more good ore out of the same material and throws away less. The company says the iron content left behind in discarded waste, known as tailings, fell 26% in 2026, meaning more of the valuable metal ends up in the final product rather than the reject pile.

Why it matters beyond one plant

The upgrade carries a green dividend that matters to Vale’s biggest customers. The plant increased its output of so-called direct-reduction pellet feed by 40%, a premium product used to make steel with far lower carbon emissions. Steelmakers worldwide are under growing pressure to cut the climate impact of their industry, and high-grade material like this is a key ingredient in cleaner steel. By producing more of it, Vale positions itself to sell into a market that should grow as the steel industry decarbonizes, turning an efficiency project into a commercial bet on where demand is heading.

For investors trying to read Vale, the significance is that this is meant to be the first of many. The company has framed the Itabira site as a model to be rolled out across its operations, which implies a steady stream of productivity gains and lower costs if the approach travels well to other plants. There is a safety angle too, since automating tasks and watching the process remotely reduces how often workers must be exposed to risky parts of the plant, a sensitive issue for a company still living under the shadow of two deadly dam disasters in the past decade. Higher output, lower waste, cleaner product and fewer people in harm’s way is a combination that, if repeated, could quietly reshape the economics of one of Brazil’s most important exporters. The open question is execution: whether results from a single showcase plant can be reproduced at scale, across older sites with different ore and different challenges.

Frequently asked questions

What did Vale actually build?

It upgraded an existing iron-ore plant in Itabira into a heavily automated, AI-run facility that monitors and adjusts more than 400 process variables in real time, lifting productivity 25%.

Why does the 25% gain matter?

Mining gains are usually small, so a quarter more output from the same site is significant, raising annual capacity to 11.2 million tonnes from 9 million while cutting waste and costs.

Will Vale expand the approach?

Yes — the company describes the Itabira site as a model plant it intends to replicate across other operations, though it remains to be seen how well the results transfer to older mines.

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