Vale, one of the world's leading iron ore producers, has officially launched the commissioning of its Capanema Maximization Project, located 80 kilometers from Belo Horizonte in the Brazilian state of Minas Gerais. This new phase of operations at the Capanema mine aims to produce an additional 15 million metric tons of iron ore per year, significantly boosting Vale’s output. The project is part of Vale’s broader efforts to modernize and streamline its operations while also prioritizing sustainability and reducing environmental impacts.
Capanema is a crucial part of Vale’s operational complex in the Mariana region, which already contributes to the company’s large iron ore production capacity. This new expansion is notable for its focus on sustainable mining practices, particularly in the areas of water conservation and waste management. The project uses a natural moisture method, meaning the ore is processed without the addition of water and without generating tailings, which eliminates the need for tailing dams. This method not only reduces environmental risks but also enhances the efficiency of the production process.
Gustavo Pimenta, the president of Vale, emphasized the significance of the Capanema expansion in terms of safety, efficiency, and sustainability. “We are resuming operations at the Capanema mine with safer, more efficient, and sustainable practices. Capanema will produce sinter feed at low cost and without generating waste. The mine will also utilize autonomous vehicles, bringing greater safety and reducing CO2 emissions,” Pimenta stated. The use of autonomous vehicles in the mining process is a key feature of the project, helping to enhance operational safety and reduce human error, while also contributing to lower carbon emissions.
The shift to dry processing, already responsible for over 70% of Vale’s iron ore production in Brazil, is central to the Capanema project. Dry processing involves fewer production steps and eliminates the need for water in the beneficiation of the ore, which has a lower environmental impact compared to traditional wet processing methods. This shift is a significant move towards the more sustainable management of resources, and it further solidifies Vale’s commitment to reducing water usage in its mining operations, an issue of increasing concern globally.
To ensure the success of the Capanema project, Vale has made substantial investments in infrastructure. A key component of these improvements is the installation of a Long Distance Conveyor System, which will transport iron ore produced at Capanema to the Timbopeba mine, located in the municipality of Ouro Preto. The TCLD will help streamline operations by connecting Vale’s various units and reducing the reliance on truck transportation in the region, which will, in turn, help reduce traffic and improve safety.
Additionally, improvements have been made to the product storage and loading facilities at the Timbopeba railway terminal. These upgrades will facilitate the smooth transport of ore along the Estrada de Ferro Vitória a Minas railway, connecting Vale’s operations to the Port of Tubarão in Espírito Santo, a key export hub. By enhancing the logistics infrastructure, Vale aims to boost the efficiency of its supply chain and reduce operational delays.
The Capanema project has created thousands of jobs, with over 6,000 workers involved at the peak of the construction phase. Vale has also prioritized hiring local labor, supporting the regional economy and providing training programs for local communities. In fact, Vale has organized eight professional development courses to equip local workers with the skills needed to operate the new equipment and participate in the expanded operations. This focus on local employment reflects Vale’s broader commitment to community development and sustainability.
Innovation is a key theme in the Capanema Maximization Project. The entire fleet of off-road trucks used in the mine will be autonomous, a cutting-edge feature that increases operational safety and efficiency. In addition, the automation of the mining processes, coupled with the integration of Capanema into Vale’s Mariana Complex via the TCLD, is expected to result in a reduction of 160 metric tons of CO2 emissions per year. This is equivalent to the emissions of 127 passenger cars annually, further demonstrating Vale’s commitment to lowering the carbon footprint of its operations.
The successful commissioning of the Capanema project represents an important milestone in Vale’s efforts to meet its iron ore production guidance of 340-360 million metric tons by 2026. The expansion not only adds flexibility to Vale’s operations but also diversifies its product portfolio, positioning the company to better serve its global customer base. By implementing innovative technologies, improving infrastructure, and focusing on sustainability, Vale is setting a new standard for iron ore production that balances profitability with environmental responsibility.
