277 APPLYING CIRCULAR ECONOMY PRINCIPLES IN MINING – VALE’S WASTE TO VALUE PROGRAM *M. Ferraz da Costa1, D.A.M. Rossi1, L.T.L. Marinho1, R.M. Tartaglia1, A.H. Oliveira 1Technical Mining Services (VALE S.A.) (*Presenting author: marilia.ferraz@vale.com) ABSTRACT The transition from a linear to a circular economy has become a central paradigm in addressing sustainability challenges in resource-intensive industries. Mining, traditionally characterized by extraction, processing, and disposal, is increasingly required to adopt practices that minimize environmental liabilities while maximizing resource efficiency. This paper examines the design, implementation, and outcomes of Vale S.A.’s Circular Mining Program, formally instituted in 2024, as a case study of circularity applied to large-scale iron ore operations in Brazil. The program was developed through a structured methodology combining executive interviews, benchmarking against peer institutions, and consensus-building workshops to establish a unified strategic vision. Five operational levers were identified to guide implementation across the ferrous mining value chain: reduction in waste rock generation, utilization of waste rock stockpiles, reduction in tailings generation, utilization of tailings in dams, and the development of co-products. Each initiative follows a mineral project development flow, encompassing chemical and contaminant characterization, plant behavior assessment, engineering feasibility, regulatory licensing, and financial evaluation through Net Present Value (NPV) analysis. Results from the program’s first year demonstrate tangible contributions to sustainability and operational efficiency. In 2025, circular sources delivered 26.3 Mt of iron ore alongside 1.77 Mt of sustainable sand. These outputs reduced CO₂ emissions by 52,77 kt, equivalent to removing 32,000 cars from circulation, and saved energy sufficient to power 100,000 Brazilian houses for one year. Beyond environmental benefits, the program mitigates risks associated with tailings dams and waste rock piles, fosters innovation through research and development of co-products, and enhances investor confidence by aligning with ESG principles. Case studies illustrate the practical application of circularity levers, including the incorporation of dolomitic itabirite at Itabira mine, the reprocessing of legacy waste rock piles at Capanema mine, the reuse of tailings at the Vargem Grande Dam and sand production from tailings at Brucutu mine. Taken together, these initiatives demonstrate how circular mining extends mine life, unlocks new revenue streams, and consolidates the role of mining in sustainable development. Vale’s experience provides a replicable framework for integrating circular economy principles into global mining practices.
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