Promoting the circular economy

Circular mining is an emerging concept that integrates sustainable and circular economy practices into the mining sector. Traditionally, mining has been associated with a linear extraction of mineral resources, where materials are mined, processed, used, and the non-recoverable portion is disposed. Circular mining, on the other hand, aims to maximize the use of mineral resources by preventing waste and tailings generation and reusing the existing materials produced during the former mining process.

In this context, circularity in mining emerges as a fundamental pillar of Vale’s strategy, becoming an essential lever for the business and creating significant opportunities for shared value.

Vale Circular Mining Program – Waste to Value

Aligned with the global movement toward sustainable mining, circularity at Vale is embodied in the Circular Mining Program – Waste to Value. Through this initiative, we aim to maximize the use of our mineral reserves while minimizing the generation of waste and tailings, as well as reducing carbon emissions across the entire value chain of the iron ore production process.

The program has already identified over 100 Circular Mining initiatives at Vale, many of which are implemented and demonstrate that circularity is a reality in our operations. In 2025, we produced 26.3 Mt of iron ore, 107% higher than in 2024, through circular sources. By 2030, we have the potential for approximately 10% of our iron ore production to come from circular mining, as a result of the expansion and consolidation of material reuse solutions throughout the production chain.

The Waste to Value initiative drives a transformation in the way mining is conducted, reshaping the future of the industry through process innovation. It reinforces Vale’s commitment to building a more responsible mining sector and stands as a key lever for sustainability, while also creating new business opportunities for the company.

Access the video and learn more about the Circular Mining Program

Circular Mining Cases at Vale

1. Waste Utilization

One of the value drivers of the Waste to Value initiative is the utilization of materials that were previously considered waste, through the development or adaptation of mineral processing routes and a higher level of innovation and technology. We are reusing iron formation waste while maintaining the quality offered in the market and meeting customer needs—in other words, we are transforming this material into something economically viable.

2.1 Phosphorus-Rich Waste Pile
Originally, the Alegria Mine recovering ore from high-phosphorus materials was not feasible. With the shift to dry processing, the Phosphorus-Rich Waste Pile became a viable ore due to its high iron content, while also contributing to the removal of this geotechnical structure. The material is now reused through blending with other materials, a key iron ore feed at the Alegria Mine in Minas Gerais.

2.2 Pilha de Estéril WH
The Capanema Maximization Project in Minas Gerais began in 2025 by reprocessing the WH Waste Pile, using material similar to that of the Capanema pit. The operation includes a long-distance conveyor belt (TCLD) connecting Capanema to the Timbopeba plant, reducing truck traffic in the region. With fewer unit operations and no water added during processing, the use of the pile is a 100% circular operation, ensuring maximum resource utilization and a more efficient, safer, and more sustainable process. Around R$ 5.2 billion were invested in reactivating the unit, which had been idle for 22 years, including modernization of facilities and integration with other mines in the region. The works lasted five years, involved about 40 companies and more than 6,000 workers at peak activity, prioritizing local labor. The operation now employs 800 people.
 

Photo: Vale Archive

Tailings Reduction and Reuse

We have developed techniques to reduce tailings generation, minimize the environmental impact of their disposal, and optimize the use of mineral resources.

2.1 Gelado Tailings Dam
At Gelado, in Carajås (PA), iron ore tailings accumulated in the Gelado dam since 1985 are being reused using 100% electric dredges for more sustainable extraction, directly contributing to C02e emissions reduction. With a production capacity of millions of tons, the project will reduce environmental impacts and support the company's decarbonization goals. Additionally, magnetic concentration—used in Parå for the first time —enhances the quality of the high-ironcontent material. The project, which reinforces Vale's strategy to develop innovative solutions for reusing tailings, is cited by ICMM as an example of circularity in the mining industry.

2.2 Vargem Grande Tailings Dam
Tailings removal from temporary stockpiles and pits, and the need for new stacking areas, pose geotechnical risks. The dam decharacterization process, with tailings reuse in the complex's plants, is expected to be completed by 2028.

Photo: Vale Archive

Co-product Development

Through investment in Research, Development, and Innovation (RD&I), we are identifying and promoting the development of products derived from iron ore production residues, transforming tailings and waste into marketable products. Highlights include materials for the construction and agricultural sectors, contributing to business sustainability and value sharing. 

3.1 Block Factory at Pico Mine 

After 10 years of research and development in technical cooperation with the Federal center for Technological Education of Minas Gerais, we inaugurated the Block Factory at Pico Mine, located in Itabirito (MG). The plant transforms mining tailings into interlocking blocks for paving roads, promoting circular economy in the iron ore beneficiation process. In 2025, more than 407,000 interlocking blocks were produced at the Pico Mine.

Photo: Vale Archive

3.2 Sustainable Sand 

The extraction of natural sand often exceeds its natural replenishment rate, which can cause severe environmental impacts, in addition to being a finite resource. On the other hand, iron ore processing can generate tailings composed mainly of silica, the primary component of sand. After seven years of research investment to find solutions for reusing these tailings, Sustainable Sand began to be produced in 2021 at the Brucutu mine, in São Gonçalo do Rio Abaixo (MG), as a substitute for sand extracted from the environment. In the same year, Vale started marketing the product for the construction industry, characterized by high silica content, low iron content, and high chemical and granulometric uniformity. In 2023, the startup Agera was created to develop and expand the business within Vale, and by the end of 2025 more than three million tonnes of sustainable sand had already been produced and delivered.

As a way of generating economic value, the initiative also contributes to reducing natural sand extraction and promoting social benefits, such as the donation of 30,000 tonnes to the Municipality of São Gonçalo do Rio Abaixo (MG) in 2025, which was used to pave the road connecting the Vargem da Lua community to the Brucutu mine.

Photo: Vale Archive