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Vale is the second-largest diversified metals and mining company in the world and the largest publicly traded company in Latin America by market capitalization (approximately US$60 billion).
It is also the world’s largest producer of iron ore and pellets and one of the largest producers of nickel. It produces copper, manganese, ferroalloys, bauxite, alumina, aluminum, coal, cobalt and platinum group metals (PGMs).
Accenture collaborated closely with Vale to install and configure the PlantTriage® software in Vale’s pelletizing plants I-IV in Vitória/ES for performance assessment, diagnoses and tuning of a total of 200 control loops.
Accenture installed and configured the PlantTriage® software in Vale’s pelletizing plants I-IV in Vitória/ES for performance assessment, diagnoses and tuning of a total of 200 control loops. Optimization services for those control loops were executed, as well as periodic consulting and training for Vale’s personnel.
The main areas of the plant executed in the project were:
Some of the most relevant activities included process analysis using PlantTriage® and trend graphs, PID controllers tuning and action plan generation for instrumentation maintenance.
The main benefits with this project were:
5.5 percent fuel (natural gas and coal) consumption reduction in Plant I and 1 percent in Plant III
20 percent variability reduction in dried ore mass of thickening underflow in Plants I and II, generating a more precise coal dosage
Temperature variability reduction in the chamber for hardening pellets of Plants I, II and III
Identification of gas valves problems in Plant IV, which presented significant losses
Payback of five months considering only the benefits of Plants I and III
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