Vale launches self-driving trucks in Brazil's largest integrated iron ore mining area

Autopilot technology has previously been applied in the Brukutu mining area, where there have been no safety accidents caused by self-driving trucks in the past three years.

Vale has launched six self-driving trucks at the Caracas iron ore complex in the Brazilian state of Para, and the number of self-driving trucks used in the mine will increase to 10 by the end of this year. Initiatives such as the use of self-driving trucks are designed to improve employee safety and make operations more environmentally friendly, sustainable and competitive. While launching self-driving trucks, the company has also provided training for employees to help them master this new digital technology.

The self-driving trucks used in the Caracas complex can carry 320 tons of ore at a time. In 2019, the company set aside a special area in Caracas to test self-driving trucks. At the end of August, the company tested the self-driving truck for the last time in the N4E mining area. On September 1, self-driving trucks were officially launched in the Caracas comprehensive mining area. In addition to self-driving trucks, the Caracas comprehensive mining area also uses four automatic drilling rigs, and the number of automatic drilling rigs will increase to seven by the end of this year.

A self-driving truck used in the Caracas comprehensive mining area. Photograph: Michael Roger / Vale

In 2016, Vale began automating operations in the Brukutu mining area in the Brazilian state of Minas Gerais. Today, there are 13 self-driving trucks operating in the Brukutu mining area. Since the launch of the project, there have been no safety accidents caused by self-driving trucks in the Brukutu mining area.

Self-driving trucks travel efficiently between the mining area and the unloading area through computer systems, global positioning systems, radar and artificial intelligence. Once the risk is detected, the truck will stop running until the obstacles on the road are cleared. The sensors of the safety system can detect larger objects, such as large rocks, other trucks and people around the road, which eliminates the risk of truck rollover and collision.

"the introduction of self-driving trucks in Caracas is another step for Vale towards its goal of becoming a safety benchmark for the mining industry and reducing carbon emissions by 33 per cent by 2030." Ant ô nio Padovezi), director of Vale's northern corridor, said: "self-driving technology reduces the opportunities for employees to be exposed to the risks inherent in mining operations, while bringing environmental benefits and strengthening our new social contract."

Put employees at the center of decision-making

There are no operators in the cockpit of self-driving trucks, but employees continue to play a role in operation. Equipment such as graders and tractors operating in the mining area will continue to be operated manually. To this end, the company will train operators of these equipment to help them learn how to work with self-driving trucks. So far, 32 operators have been trained, and the company plans to complete the training of 120 operators by the end of this year. The training time for each operator will reach 208 hours, and the cumulative training time will reach nearly 25000 hours.

An operator sitting in a control room away from the mining area. Photograph: Michael Roger / Vale

In the next 12 months, truck suppliers will assist in the operation of self-driving trucks. After that, Vale plans to take full responsibility for the operation of self-driving trucks. At that time, new employment opportunities will emerge in the control room far from the mining area.

"the implementation process of automated operations always puts employees at the center of decision-making." "the introduction of digital technology promotes the development of employees' professional skills and prepares them for the digital transformation of the mining industry," said Pedro Benfica (Pedro Bemfica), project manager of Vale Automation.

Environment and Competitiveness

Automatic operation will bring environmental benefits. With the continuous stability of truck performance and the continuous improvement of average speed, fuel consumption will be reduced by about 5%, and carbon dioxide and particulate matter emissions will also be reduced. According to market data, self-driving technology is expected to extend the service life of trucks by about 7%, which will reduce the amount of waste such as spare parts and lubricants, and the technology will also extend the service life of tires by about 25%. This will reduce the number of discarded tires.

Automated operations will also improve Vale's operational competitiveness. The operational efficiency of the mine will be improved, which means that productivity per hour will be increased, and maintenance costs are expected to be reduced by 3%.

Expand the scope of automation project implementation

The scope of Vale's automation projects continues to expand, with a total investment of about $34 million in 2021. By the end of this year, operating areas in the Brazilian states of Para, Minas Gerais, Maranion and Rio de Janeiro will use 23 self-driving trucks, 21 automatic drilling rigs and four yards using automatic stackers and reclaimers. Automated operations are also available in many operating areas outside Brazil, with automated drilling rigs and automated buckets in Canada and automated yard equipment in Malaysia.

Safety innovation

Innovation is the key to Vale's concerted efforts with society to improve life and change the future. Vale focuses on safety, reliability, a low-carbon agenda and the creation of shared value. In 2021, Vale incorporated safety innovation projects into its Safety Transformation Plan and set three goals for it, namely: to ensure safety processes, to accelerate operational control, and to keep employees away from hazardous operations through technologies such as remote control, automation and robotics. Projects carried out by the Security Transformation Program include the introduction of self-driving vehicles, the application of operator fatigue detection systems, and the use of augmented reality technology for detection and maintenance operations.