The S11D Eliezer Batista Complex of Vale, located in Canaã dos Carajás, Brazil, is a massive mining facility that includes a port, a railway, a processing plant, and a mine. The mine uses a truckless technology and has a production capacity of 90 million tonnes per year (MTPA). A network of 30 km (18.6 miles) of connected conveyors transports the extracted material directly from the mine to the processing plant. This innovative method reduces fuel consumption by 70% and also decreases waste production, such as tires, filters, and lubricants. The mine has an operational lifespan of thirty years.
The iron ore deposit is connected to the main Carajás railway line by a 101-kilometer (63-mile) railway extension. The expansion and modernization of the railway have increased its capacity to 230 MTPA. According to the ILOS Institute, this railway is the most efficient in Brazil. With four locomotives and 330 wagons, the ore train can transport 33,000 tonnes of iron ore.
The railway crosses challenging terrain, with sections prone to rockfalls and other debris on the tracks. To mitigate these risks, rockfall protection nets have been installed at various locations along the extension to contain falling rocks and ensure safety.
The high-grade iron ore, including its ultrafine fractions, can be recycled and reused thanks to natural moisture processing methods, eliminating the need for tailings dams. Over the mine’s lifespan, 300 million tonnes (MT) of ore recovery is expected.
