Vale inaugurated its first high-tech processing plant using artificial intelligence (AI) after modernizing a facility in Minas Gerais state, achieving a 25% productivity gain in less than two years. 

The Conceicao 2 unit can now produce up to 11.2 million tons of iron ore annually, up from 9 million tons in 2024.

The upgrade incorporated cutting-edge automation, monitoring, and data intelligence to enhance the optimization of over 400 variables in the beneficiation process. The pilot project also raised the proportion of direct reduction pellet feed by 40%, a key product for steel decarbonization, and enhanced mineral recovery.

Vale said digitalization has reduced manual interventions and improved safety, and it plans to use the model as a reference for other units.