287 Figure 8 – A) Vargem Grande Dam in the process of decharacterization; B) Tailings placed in bays for preliminary drying. 3.5. Development and Exploration of Co-products: Sustainable Sand The development of Sustainable Sand from iron ore tailings represents a technological solution aimed at reducing the reliance on tailings dams while simultaneously generating a commercially viable product. By processing fine-grained residues from beneficiation plants, the material is transformed into sand with physical and chemical properties suitable for use in construction and infrastructure applications. Vale created Agera, a spin-off company focused on sand commercialization and R&D of coproducts. The Agera is currently implemented at Vale’s Brucutu mine, located in Minas Gerais, Brazil, close the city of São Gonçalo do Rio Abaixo. This approach not only mitigates the risks associated with long-term tailings storage but also contributes to resource efficiency by converting what was previously considered waste into a standardized input for industrial supply chains. The initiative demonstrates how mineral byproducts can be re-engineered to meet regulatory and performance requirements, offering a pathway toward more sustainable waste management in large-scale mining operations. 4. CONCLUSIONS Vale’s Circular Mining Program consolidates dispersed initiatives into a structured framework that applies circular economy principles directly to iron ore mining. By focusing on five operational levers, waste rock reduction, utilization of stockpiles, tailings reduction, reuse of tailings in dams, and development of co-products, the program demonstrates that circularity can be integrated into core mining processes. Circular mining thus signals a transformation in the way natural resources are exploited, rewriting the future of the sector and promoting a more innovative and environmentally committed model of resource development. Future progress depends on advancing mineral processing technologies, adopting digital tools for waste management, and ensuring regulatory alignment. Collaboration among companies and public authorities will be essential to scale circular practices across the sector. In sum, the program illustrates how circular mining can reduce impacts, optimize resources, and provide a replicable model for sustainable iron ore production.
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