Vale's Major New Carajás Program: Expanding Iron Ore and Copper Production to Drive Global Decarbonization
In a landmark move, Vale, a global mining leader, has unveiled the New Carajás Program in Brazil’s Carajás region—a hub rich in iron ore and copper, to maintain high-quality mineral production and increase output in the coming decades. As the company celebrates its 40th anniversary in the Amazon, this program highlights Vale's continued commitment to sustainable mining practices, advancing its role in Brazil’s energy transition and positioning itself as a leading force in the global decarbonization effort.
The official announcement, made on February 14, 2025, coincided with a ceremony attended by President Luiz Inácio Lula da Silva and marks a significant investment for Vale in the country’s mining industry. The program, which is set to run from 2025 to 2030, will focus on increasing iron ore production to meet the global demand for green steel and copper, essential in building the infrastructure for electric vehicles and renewable energy technologies. The New Carajás Program is part of Vale's long-term vision of being at the forefront of sustainable mining, contributing to the global energy transition, and driving Brazil's leadership in the low-carbon economy.
Strategic Importance of Carajás: Brazil's Mineral Hub for the Energy Transition
The Carajás region is located in the state of Pará, northern Brazil, and is one of the richest areas in the world for both iron ore and copper. This area has become increasingly crucial in the context of global decarbonization efforts as the world transitions to cleaner, greener technologies. Both iron ore and copper are integral to the energy transition, iron ore is key to producing green steel for the construction and automotive industries, while copper is essential in the manufacturing of electric vehicles, solar panels, wind turbines, and other renewable energy infrastructure.
Vale has committed to utilizing the potential of Carajás for expanding the production of these critical minerals. The new program seeks to strengthen Brazil’s position as one of the world’s top suppliers of critical minerals required for clean technologies, ensuring the country plays an active role in combating climate change and meeting global sustainability goals.
Key Investments and Production Goals: A Bold Path Toward a Low-Carbon Economy
At the core of the New Carajás Program is an investment of R$70 billion (approximately $13 billion) over the next five years (2025–2030). This investment will focus on expanding iron ore and copper production, ensuring Vale’s production lines meet global demand while maintaining the high-quality standards required for green steel and EV manufacturing.
Vale plans to increase iron ore production in the Carajás region to an impressive 200 million metric tons per year by 2030, a figure driven by the expansion of the Serra Sul Mine, S11D, which is the world’s largest iron ore mine. Additionally, Vale will ramp up copper production by 32%, reaching approximately 350,000 metric tons annually. These increases will be supported by Vale’s cutting-edge mining and processing technologies, allowing the company to improve production efficiency while minimizing the environmental impact of its operations.
In the context of Brazil’s economic growth, the New Carajás Program will have a transformative impact on Pará’s economy. The program is expected to generate approximately R$80–100 billion annually for the state, bolstering economic development and creating job opportunities. Projections suggest that the increase in production will lead to an additional R$15 billion in export revenues from Pará by the time the program is fully operational.
Sustainability and Innovation: Vale's Decarbonization Commitments and Circular Solutions
Vale has long been committed to the principles of sustainability and environmental responsibility. The New Carajás Program deepens this commitment by incorporating innovative mining technologies and focusing on the energy transition. One of the primary objectives of the program is to produce high-quality iron ore, which significantly improves blast furnace efficiency and reduces steel mill emissions, playing a crucial role in the global transition to green steel.
In addition to iron ore, Vale's expansion plans also include copper, a key metal in the development of electric vehicles and renewable energy solutions. The company’s production of nickel and copper will directly support the global demand for clean energy technologies, as both are critical components of electric vehicle batteries and renewable infrastructure like wind turbines and solar power plants.
Vale is also investing in circular solutions that will reduce the environmental impact of mining. One such initiative is the Gelado Project, which focuses on the reuse of mining tailings to produce iron ore. By 2030, Vale aims for 10% of its total iron ore production to come from circularity-based products, like those produced by the Gelado Project. This project will produce up to 6 million metric tons of iron ore annually from tailings reuse, contributing to Vale’s goal of creating a tailings-free mining operation and helping it move toward low-carbon products.
Furthermore, Vale’s efforts in reducing CO₂ emissions in its operations are significant. Briquettes, an innovative product developed by Vale, can reduce emissions from the steel industry by up to 10%. As a result, Vale is not only contributing to decarbonization in the mining sector but is also directly supporting the steel industry’s transition to cleaner, more sustainable production methods.
Vale's Vision for the Future: Leading the Way in Sustainable Mining
The New Carajás Program represents Vale’s vision for the future of mining, one that balances economic growth with environmental sustainability. Gustavo Pimenta, CEO of Vale, stated, “This program is a major step in expanding our mining operations while ensuring that we contribute to climate change mitigation and sustainable growth for Brazil. We are proud of our long-term efforts to lead the mining industry toward cleaner technologies and practices.”
Vale’s continued focus on innovative technologies such as dry mining processes, which minimize the environmental impact of mining while improving efficiency, demonstrates its commitment to pushing the boundaries of sustainable mining. With 60% of Brazil’s iron ore exports coming from the Carajás region, Vale is not only driving local economic growth but also positioning Brazil as a leading global supplier of critical minerals essential for the global energy transition.
Key Takeaways:
• Vale's New Carajás Program involves a R$70 billion investment ($13 billion) from 2025 to 2030, focused on increasing iron ore and copper production.
• Iron ore production in Carajás is projected to reach 200 million metric tons annually by 2030, while copper output will increase by 32% to approximately 350,000 metric tons annually.
• The program will contribute R$80–100 billion annually to Pará's economy, with exports projected to grow by R$15 billion.
• Vale’s sustainability initiatives include producing high-quality iron ore for green steel, circular solutions like the Gelado Project for tailings reuse, and developing briquettes to reduce steel mill emissions by up to 10%.
• Vale aims for 10% of its total iron ore production to come from circular products by 2030.
• Vale’s use of innovative technologies like dry mining and tailings reuse reflects its leadership in low-carbon mining practices and its role in combating climate change globally.
