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Vale S.A. and ABB have entered into a strategic agreement to expand the use of artificial intelligence (AI), digitalization, and industrial automation technologies across Vale’s iron ore processing plants in Brazil. The collaboration represents a major step toward building more intelligent mining operations, where data-driven decisions and automated control systems can optimize complex mineral processing workflows.

The agreement, confirmed on August 11, 2026, focuses on integrating advanced digital solutions into Vale’s existing production infrastructure. Rather than applying automation only to individual processes, the initiative aims to create a connected operational environment where production data, equipment performance information, and process parameters can be analyzed continuously through AI-powered predictive analytics software.

ABB will contribute its expertise in industrial automation, control systems, and digital solutions to help Vale improve operational efficiency across its mining assets. The partnership reflects a growing trend among global mining companies to adopt smart mining technologies that combine automation platforms, machine learning algorithms, and real-time monitoring capabilities.

For industrial operators, the combination of AI and automation provides new opportunities to optimize production without requiring complete replacement of existing infrastructure. Advanced analytics can identify process deviations, predict equipment behavior, and automatically adjust operating parameters to maintain stable performance.

ABB’s automation portfolio, including industrial control solutions and digital platforms, plays an important role in modernizing large-scale production environments. Companies operating complex facilities often rely on technologies such as distributed control systems, industrial networks, and intelligent field devices to achieve higher reliability and operational visibility. More information about ABB automation solutions can be found through industrial automation resources such as ABB controllers and CPU solutions and ABB System 800xA platforms.

The first major implementation phase was completed at Vale’s Conceição II processing plant, located in Itabira, Minas Gerais. The facility has become a reference project for evaluating how artificial intelligence can improve performance at mature mining operations.

According to Vale, the AI-driven optimization program at Conceição II has delivered significant operational improvements since implementation began in 2024. The plant achieved approximately 25% productivity growth, increased premium ore production by 40%, and reduced iron losses in tailings by 26%.

These results demonstrate the potential of digital transformation in existing mining facilities. Instead of relying only on new construction projects, mining companies can use automation upgrades and intelligent software to unlock additional value from established assets.

The Conceição II pilot project involved an investment of approximately R$200 million. Vale expects similar technologies could generate average productivity improvements of around 25% when expanded to additional processing units.

A key advantage of the AI system is its ability to analyze ore characteristics, production conditions, and equipment performance simultaneously. By combining these data sources, the platform can support operators in making faster decisions and maintaining optimal process conditions.

Reducing tailings losses is also an important objective of the project. Improved mineral recovery not only increases production efficiency but also supports environmental goals by reducing waste generation and improving resource utilization.

The success of the Conceição II project highlights how AI-based process optimization is becoming an essential technology for the mining sector. As ore grades decline globally and operational challenges increase, mining companies are increasingly investing in digital platforms that can improve recovery rates while maintaining safety and sustainability standards.

Vale plans to gradually expand the technology across its mining operations, with a broader rollout expected over the next three to five years. The company’s strategy demonstrates the increasing importance of automation, artificial intelligence, and industrial data management in the future of mineral processing.

The partnership between Vale and ABB also reflects a wider industrial movement toward autonomous and connected operations. From mining and metals to energy and manufacturing, companies are adopting advanced automation systems to improve productivity, strengthen operational resilience, and create more sustainable production models.

As AI technologies continue to evolve, mining operations are expected to become increasingly dependent on predictive maintenance, automated control strategies, and intelligent decision-support systems. The Vale and ABB collaboration represents one of the latest examples of how industrial automation is reshaping traditional production industries.

Written by: Daniel Mercer. Daniel is an industrial automation technology writer with more than 12 years of experience covering PLC systems, digital manufacturing, process control, and smart industry solutions. His work focuses on how automation technologies improve reliability, efficiency, and operational performance across global industries.