THE LEADER VOLUME 18 • NUMBER 10
Vale invests for the future
Editorial Director Paul Moore BSc ( Hons ), MSc Email : paul @ im-mining . com
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Global iron ore and base metals mining major Vale recently gave its 2023 XXIII Investor and Analyst Tour of its Northern System operations , which is its high volume iron ore hub in the state of Pará , Brazil , and which includes three main mining areas : Serra Norte , Serra Leste and S11D . It also includes its Morro do Azul manganese operations . The presentation was given on September 5 by Marcello Spinelli , EVP Iron Ore Solutions ; Carlos Medeiros , EVP Operations ; and Gustavo Pimenta , CFO . Long term , Vale wants to ensure its premium iron ore portfolio can support the transition to netzero emission steelmaking .
At Serra Norte , the world ’ s largest iron ore mining area , the N4W , N4E , N5 and Morro 1 mines are currently operating – 12 open pits in total – generally referred to together as the Carajas mining complex , with N3 due to come online in 2025 and beyond that N1 / N2 after 2030 . Serra Norte produces 140 Mt / y and is distinct from the other two Northern System mining areas in Para – Carajas Serra Sul or S11D , one of the world ’ s largest in-pit crushing and conveying mines with four separate truckless systems , and Serra Leste in the municipality of Curionopolis . IM recently got some additional direct insight into the major mining related investments Vale is making at S11D , as well as an update on its automation progress both at its Northern System operations but also elsewhere such as at Brucutu and Itabira mines in its Southeastern System .
At Carajas Serra Sul ( S11D ) capacity is now 90 Mt / y but a major expansion is underway known as Serra Sul 120 , referring to the fact that the project will see production reach 120 Mt / y by 2026 . Work has now reached 51 % physical progress . The project consists of the opening of new mining areas with the installation of a semi-mobile crusher in Area 5 , the implementation of new processing lines , the expansion of storage areas and mine equipment , the expansion of the maintenance workshop , as well as other new buildings and works . The project also includes the duplication of the long-distance belt conveyor , parallel to the current one and with the same capacity . With a length of 9 km , the conveyor is responsible for transporting iron ore from the mine to the plant , given that it was built in an area outside the Carajás National Forest , and ensures less interference with the environment . The total investment for Serra Sul 120 stands at about $ 1.5 billion .
With a separate investment of $ 755 million , the Compact Crusher Project at S11D will enable the processing of various minerals , including harder jaspilite and transition material . The scope involves the implementation of primary crushing , secondary crushing and a belt conveyor system with a capacity of 45 Mt / y . This is in addition to mine equipment , support facilities , new substations and a drainage system . An investment in maintaining the existing operation , the project for now is 13 % complete and when finished will give S11D more flexibility and should be operational in H2 2026 . Jaspilite is a hard rock from the Carajas formation containing bands of jasper and iron minerals with 42 % average Fe and 36 % average SiO 2 . It is a challenge due to its high abrasiveness and compressive strength .
On autonomous fleet progress , Vale has reached 87 autonomous equipment units in operation , of which 82 are in Brazil . This includes 14 Caterpillar haul trucks in Brucutu and 14 Komatsu haul trucks in Carajas . The Carajas trucks are Komatsu 930E-ATs using its FrontRunner technology & Modular DISPATCH fleet management system while the Brucutu units are Caterpillar 793F CMD models using Command for hauling , part of its MineStar™ suite of technology . Onto drill rigs , and it now has 13 auto drilling rigs in Itabira , two in Brucutu and eight in Carajas . These are mainly a mix of existing Epiroc and Caterpillar drills that have been retrofitted using FLANDERS ARDVARC technology . In addition , Vale has 18 autonomously operated stockyard machines in Sao Luis and 13 in Carajas . There are also five autonomous stockyard machines in operation in Malaysia . These are mainly railmounted bucketwheel stacker-reclaimers .
A final note on mining trucks and Vale ’ s decarbonisation strategy . The miner was originally looking at deploying a trolley assist line in Carajas on which initial installation had been earmarked for 2023 – however – the company told IM that its outlook has now changed and that it is instead focused on developing alternative fuels for its mines and railways , such as green ammonia for locomotives and ethanol for haul trucks , as well as testing electric batteries for smaller equipment units .
Paul Moore Editorial Director paul @ im-mining . com
OCTOBER 2023 | International Mining 3