Vale expands autonomous haulage fleet in Carajás through new partnership with Caterpillar and Sotreq

Vale, Caterpillar Inc. and Sotreq have taken another major step toward the future of smart mining. The three companies have signed a new agreement to expand the fleet of autonomous haul trucks operating in Vale’s Northern System, located in the Carajás region of Pará.

Future progress

Over the next five years, autonomous haulage technology will be gradually rolled out across the Serra Norte and Serra Sul units. The goal is clear: further elevate operational efficiency, strengthen safety standards, and advance sustainability across Vale’s iron ore operations. The transition will be supported by a dedicated employee development program to prepare teams for strategic, digitally enabled roles.

Present autonomous hauling

Today, the Northern System operates 14 autonomous haul trucks capable of carrying up to 320 tons. Under the new agreement, the fleet is set to grow to approximately 90 autonomous trucks by 2028, all powered by Cat MineStar Command for hauling, including models able to transport up to 400 tons.

Profits

The impact is already measurable. Autonomous fleets at Vale’s operations have delivered up to 15% gains in operational performance and up to 7.5% reduction in fuel consumption, contributing directly to lower carbon emissions. In parallel, the shift removes workers from hazardous areas and creates safer, more inclusive work environments.

Since autonomous implementation began in the Northern System in 2019, Vale has trained more than 260 professionals for emerging digital roles aligned with global best practices.

Carlos H. Medeiros, has emphasizes : “The use of autonomous transport technologies in our operations in the Northern Corridor is a fundamental strategy to strengthen our culture of operational excellence and prepare our teams to lead the challenges of increasingly efficient, competitive, and sustainable mining.”

Rafael Jabur Bittar, has added: “By integrating autonomous systems, artificial intelligence, and advanced data analysis, we are modernizing our mining operations in the Northern Corridor, becoming a global benchmark in smart mining, promoting the transformation of the industry, and connecting us to international best practices.”

Caterpillar echoes this excitement. Marc Cameron notes: “By equipping Vale’s haul trucks with our autonomous technology, we will be delivering scalable solutions that meet their needs across a mixed fleet.”

Constans improvment

The expansion will coexist with other innovative approaches, particularly in Serra Sul, where the truckless system a long-distance belt conveyor network already reduces fuel use and significantly lowers emissions. Vale’s autonomous journey began in 2018 at the Brucutu mine in Minas Gerais, and the company now operates over 70 autonomous machines, including trucks, drills, and yard equipment.