Vale Launches AI Model Plant in Itabira

Industry context: Real-time, closed-loop AI applied to industrial process control changes MLOps requirements for practitioners by shifting focus to high-frequency telemetry, model latency, and integration with control systems. According to Vale, on June 10 the company inaugurated its first AI-powered "Model Plant" at the Conceição 2 unit in Itabira, Minas Gerais, with an annual capacity of 11.2 million tonnes per year (Per Vale). Per Vale, the modernisation automated roughly 7,300 instruments, added more than 100 monitoring cameras, and uses data intelligence to control and optimise over 400 process variables. Vale quotes Carlos Medeiros, its Vice President of Operations: "The model plant is more than a project: it represents a new way of operating," (direct quote in Vale release). Environment & Energy Leader and other industry outlets report the plant achieved a 25% productivity gain, a 40% increase in direct reduction pellet feed output, 26% lower iron lost to tailings, and 92% water reuse. Mining Magazine reports the modernisation followed about R$200 million (roughly USD 40 million) of investment.