Rockwell Automation targets 100% new water reduction in Carajás iron ore processing plant

Mining, mineral processing, and industrial automation sectors are under increasing pressure to reduce water consumption and environmental impact while maintaining production efficiency. At the Carajás Mining Complex in Brazil, Vale is retrofitting its Plant 1 facility to operate entirely with natural moisture processing, aiming to reduce new water use by 100% and eliminate tailings waste while increasing production capacity.

Rockwell is acting as the end-to-end integration partner for this modernization project, coordinating automation, electrical systems, and equipment from six different suppliers. The retrofit involves upgrading systems within limited shutdown windows, requiring precise planning to ensure the plant resumes operation at specified performance levels immediately after each intervention.

Automation platform for waterless processing
A central component of the upgrade is Rockwell’s PlantPAx distributed control system, which is used to monitor and control plant operations, including the transition to waterless processing. This type of control architecture enables centralized supervision of complex processes, helping operators maintain stable throughput and process consistency under changing operating conditions.

In the context of natural moisture processing, control systems must manage variations in ore properties, such as moisture content and particle size, which directly affect crushing, screening, and material handling performance. Automated control helps maintain optimal operating parameters and reduces the risk of process disruptions.

Integrated electrical and power management systems
The project also includes the deployment of engineer-to-order panels, drives, and power management components that form part of the plant’s electrical infrastructure. These systems are designed to support reliable operation of processing equipment, including conveyors, crushers, and screening units.

By integrating electrical and automation systems within a unified framework, the project aims to improve coordination between equipment and reduce downtime associated with system mismatches or integration issues.

Lifecycle engineering and system integration
Rockwell’s Lifecycle Services covers the full project scope, including system design, commissioning, and ongoing optimization. This approach is particularly relevant in retrofit projects where existing infrastructure must be adapted to new process requirements without extensive production interruptions.

The integration of multiple suppliers and systems into a single operational environment requires standardized communication protocols and coordinated engineering to ensure interoperability and maintainability over the plant’s lifecycle.

Environmental and operational impact
The transition to natural moisture processing eliminates the need for additional water in ore processing and removes the generation of tailings, which are typically associated with slurry-based beneficiation processes. This reduces both water demand and the need for tailings storage facilities.

At the same time, maintaining or increasing production capacity requires precise control of dry processing operations, where material handling efficiency and dust management become critical factors.

Located within the National Forest of Carajás, the project reflects operational constraints linked to environmental protection and regulatory requirements. The modernization also supports regional development by maintaining industrial activity in a remote area while aligning with sustainability objectives in the mining sector.

Edited by Natania Lyngdoh, Induportals Editor — Adapted by AI.

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