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

Vale activated its first AI-driven processing plant in Itabira, Minas Gerais, on June 10, 2026. The upgrade raised annual iron ore output to 11.2 million tonnes from 9 million in 2024, a 25% gain. The project cost about R$200 million ($38.8 million) and enables remote supervision from control rooms. The AI system monitors over 400 variables using more than 100 cameras and 7,300 instruments. Tailings fell 26% in 2026, increasing the share of high-grade ore in the final product. Direct-reduction pellet feed rose 40%, aligning with steelmakers' push to lower carbon emissions.