Brazilian mining company Vale has announced plans to stop using water in iron ore processing at its Carajas complex in northern Brazil by 2027, according to a report by Reuters.
This initiative is expected to eliminate the generation of tailings, thus negating the need for new dams and reducing operational costs.
Additionally, Vale is focused on expanding pellet feed production by reutilising mine waste at the Carajas complex.
Carajas, located in the Para state of Brazil, is recognised as the largest open-pit iron ore mining complex globally.
The company's transition towards dry processing is well under way, with 90% of its Northern System operations already employing this method.
Vale director Gildiney Sales was quoted as saying: “By end-2027 they will be 100% dry. The Northern System will be 100% on natural moisture.”
In 2024, the area produced 177.5 million tonnes (mt) of iron ore, accounting for more than half of Vale's total production.
The Gelado Project, which has repurposed tailings from the Gelado dam since 1985, is projected to double its output in 2026 compared to this year.
With an estimated production of around 5mt next year and 6mt in 2027, Vale is aiming for 10% of the Gelado Project’s annual production to originate from "circular mining" by 2030, the report said.
However, Vale's ambition to increase nickel production at the Onca Puma complex in Brazil has faced a setback.
Brazilian power grid operator ONS has denied the company's request for an increase in power consumption, which is crucial for operating a new furnace as part of a $555m (3.08bn reais) expansion project.
