Vale has begun commissioning the Capanema Maximization Project in Minas Gerais, Brazil, aiming to bolster its iron ore production capacity by approximately 15 million tonnes per year (mtpa).

The project, part of Vale’s Mariana Operational Complex, aims to reach its projected iron ore production of 340–360mtpa by 2026.

The operation will employ natural moisture processing, negating the need for water usage and tailings dams.

The Capanema project marks a significant expansion of Vale’s natural moisture or dry processing operations, which currently represent more than 70% of its total iron ore production in Brazil.

This method streamlines production steps, reduces environmental impact, and eliminates both water use in processing and waste generation.

To restart operations in the Capanema mine, Vale has invested in the reactivation process and implemented a long-distance belt conveyor system (LTC) to transport ore to Timbopeba.

The LTC minimises regional truck traffic by connecting units internally. Additionally, upgrades have been made to the storage and loading areas at the Timbopeba railway terminal, facilitating transportation to the Port of Tubarão via the Vitória-Minas Railway.

The project’s construction phase saw the involvement of around 40 companies and more than 6,000 workers, with a focus on employing local labour.

An autonomous fleet of off-road trucks has been introduced at the site to enhance safety and operational efficiency.

Automation and the integration of the Mariana Complex mines through a truckless conveying and loading system are projected to reduce emissions by 160 tonnes of CO₂ equivalent annually, equivalent to the emissions from 127 cars.

Vale CEO Gustavo Pimenta said: “We are resuming operations at the Capanema mine with safer, more efficient and sustainable practices. Capanema will produce sinter feed at a low cost and without generating waste. The mine will use autonomous trucks, providing greater safety and reducing CO₂ emissions from the operation.”