Vale is also focused on expanding pellet feed production by reutilising mine waste at the Carajas complex.
The transition is well underway, with 90% of Vale’s Northern System operations at Carajas already using dry processing methods. Vale director Gildiney Sales stated: “By end-2027 they will be 100% dry. The Northern System will be 100% on natural moisture.” In 2024, the Carajas complex produced 177.5 million tonnes of iron ore, representing over half of Vale’s total output.
Vale is also focusing on sustainable practices by expanding pellet feed production through the reuse of mine waste. The Gelado Project, operational since 1985, reprocesses tailings from the Gelado dam. It is expected to produce 5 million tonnes in 2026, doubling its output compared to 2024, and reach 6 million tonnes by 2027. By 2030, Vale aims for 10% of the project’s annual production to come from “circular mining” practices, enhancing resource efficiency.
The move to dry processing and waste reutilization supports Vale’s commitment to sustainable mining practices, reducing environmental impact while maintaining production efficiency at Carajas. The initiative aligns with global efforts to promote responsible resource management in the mining industry.
However, Vale faced a challenge in its efforts to expand nickel production at the Onca Puma complex in Brazil. The national power grid operator, ONS, rejected Vale’s request for increased power consumption needed to operate a new furnace for a $555 million expansion project. Despite this setback, Vale continues to prioritize innovation and sustainability across its operations.
This strategic shift at Carajas underscores Vale’s leadership in adopting environmentally conscious mining practices, contributing to both operational efficiency and regional economic development in Para state.
