Vale has been developing techniques to reduce tailings generation that help lower environmental impacts and maximize the use of mineral resources. Below are a few examples. The innovative Gelado iron tailings recovery process, with operations that began in 2023 in the state of Pará, Brazil, uses 100% electric dredges for sustainable extraction, reducing CO₂ emissions, with a projected production capacity of 25 million metric tons by 2030. In addition, Vale is applying magnetic concentration technology for the first time (Fig. 1). As part of the mischaracterization process of the tailings dam at the Vargem Grande mine in the state of Minas Gerais, Brazil, studies are underway to begin operations in 2028 to reuse the tailings removed and processed at the plant to produce pellet feed. This will reduce disposal in pits of depleted mines and the need for new areas to build waste piles, minimizing geotechnical, environmental, and social risks. Another stream of circular economy initiatives at Vale is creating value from the waste rock generated in mining—leveraging material previously considered waste, through innovation and technology, to transform this residue into economically viable material. Figure 1 – Reuse of iron ore tailings at the Gelado tailings dam Originally, at the Alegria mine in the state of Minas Gerais, Brazil, processing was wet, and recovering ore with high phosphorus content was not possible. However, by applying dry processing, the Phosphorous Waste Rock Pile became an option for feeding the plant as high-grade ore due to its high iron content, while also supporting the removal of this geotechnical structure. It is currently reused through blending with other ores, and the Phosphorous material has become an important mining front. The Capanema Maximization project, in Minas Gerais, Brazil, began by restarting the WH Waste Rock Pile. The operation includes a long-distance belt conveyor connecting Capanema to the Timbopeba plant, reducing truck traffic in the region. With fewer unit operations and dry processing, use of the pile is a 100% circular operation, ensuring maximum utilization of the
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