Carajás Railroad Archives - International Mining

Vale has started to implement, in partnership with Vivo, an unprecedented technology infrastructure to extend the reach of the 4G internet signal along the Carajás Railroad, which connects the states of Maranhão and Pará, covering 28 cities in Brazil.

The initiative includes the installation of 49 new telephone towers and the activation of the signal on another 27 towers already installed, as well as the acquisition and installation of new equipment. The investment, worth around BRL240 million ($50 million), should be completed by 2025 and will benefit communities close to the railroad and the railroad operation, as well as improving connectivity on the Passenger Train.

Eduardo Bartolomeo, Vale’s CEO, said: “This initiative is in line with our commitment to invest in projects of shared value with society. It meets not only Vale’s needs – modernizing the technology used to exchange data during the movement of trains – but also those of the communities, with the provision of a 4G signal along the entire route of the Carajás Railroad, and also the users of the Passenger Train, improving connectivity during the journey.”

Alex Salgado, VP of Business at Vivo, said: “Our private network project plays a leading role in the materialisation of initiatives that accelerate industrial digitalisation, leveraging technologies such as IoT, big data, artificial intelligence and analytics within the operation, transforming data into intelligence, ensuring greater safety, cost reduction and efficiency gains. And in addition to technological advances within Vale’s railroad operation, the companies will go further and share with the population the benefits of excellent connectivity in all the municipalities close to the railroad.”

The new 4G-based private network infrastructure will bring more security and efficiency to the operation of the Carajás Railroad, which is already considered the safest railroad in Brazil by the National Land Transport Agency, Vale says. All communication on the railroad will be changed from analogue to digital, speeding up access to data generated by the trains and making it possible to implement even more innovative systems in the future.

The railroad will have real-time video transmission, giving the driver greater visibility of what is happening on all sections of the track. Information generated by telemetry on the train’s performance will also be available in real time along the entire length of the railroad. In addition, cell phone communication between employees will be more stable.

The investment in the railroad is part of an initiative started in 2019, when Vale signed the first contract with Vivo to install a private 4G network in its operations.

Paulo Pires, Chief Technology Officer, said: “Since 2019, this network has already been deployed in Carajás, where it enables the operation of 22 pieces of autonomous equipment, including haul trucks and drilling rigs, and in Itabira, where it supports dam monitoring.”

A significant social impact of this technology project is the provision of free internet access points along the railroad, in high-traffic locations such as hospitals, schools and community centers. Vale’s teams have already started dialoguing with leaders and representatives of public authorities to determine which locations will benefit. There will be around 280 access points.

In addition, by the end of 2024, all 15 passenger stations along the Carajás Railroad will have a free internet signal for users.

Vale has announced a partnership with Wabtec Corporation to advance the decarbonisation of the company’s rail operations. The deal includes an order for three of Wabtec’s FLXdrive battery locomotives and a collaboration to test ammonia as a potential clean, alternative fuel to replace diesel.

The three 100% battery-powered FLXdrive locomotives will be used on the Carajás Railroad (EFC), which runs the world’s largest iron ore train consisting of 330 railcars transporting 45,000 t.

Today, three to four diesel locomotives pull the train. Once delivered, the FLXdrives will join the diesel locomotives to form Brazil’s first hybrid consist pulling the train uphill for 140 km in Açailândia, in the state of Maranhão, where fuel consumption is the highest. The FLXdrives will replace the two diesel locomotives, known as “dynamic helpers”, that are used to pull the train uphill today, Vale says.

Wabtec will build the FLXdrive locomotives at its plant in Contagem (state of Minas Gerais). The locomotives’ delivery is forecast for 2026.

Vale’s Director of Energy, Ludmila Nascimento, said: “Initially, we are maximising energy efficiency, replacing the diesel locomotives in the dynamic helper with battery ones, but the idea is that, in the future, the other locomotives on the train can be fueled by ammonia. This way, we would have a clean operation at EFC. This agreement is the first of many that we are seeking in order to accelerate the decarbonization of our railway operation.”

Vale and Wabtec will work together on a study to use ammonia as a clean alternative fuel, which does not emit CO2. The study will initially be carried out as lab tests to validate performance, emission reductions and feasibility. Among the advantages of ammonia is the fact that it allows the locomotive a longer range than other carbon-free fuels. In addition, ammonia has a high-octane rating and an established large-scale distribution infrastructure, according to Vale. The two companies will carry out the study in a laboratory over the next two years.

The FLXdrive locomotive’s energy management system recharges the batteries along the route as the train brakes.

Alexandre Silva, Manager of Vale’s Powershift Program, said: “It’s what we call regenerative energy produced by dynamic braking. Today, that energy is lost when a traditional locomotive brakes. In the downhill sections, we will be able to recharge the batteries, without having to stop the train’s operation.”

Vale introduced the Powershift Program to study alternative technologies to replace fossil fuels with clean sources in the company’s operations.

The FLXdrive locomotives are estimated to save 25 million litres of diesel per year, considering the consumption of all the railway’s trains that use the dynamic helper. These savings would reduce carbon emissions by approximately 63,000 t, the equivalent emissions of around 14,000 passenger cars per year, it says.

Danilo Miyasato, President and General Manager of Wabtec for Latin America, said: “Technological advances in battery power and alternative fuels are accelerating the decarbonisation journey for railroads. Vale’s innovative approach to adopting alternative fuels for its locomotives will benefit its customers, shareholders and communities. The FLXdrive provides Vale productivity, safety, fuel economy and emission reductions for its rail network.”

In 2020, Vale announced an investment of between $4 billion and $6 billion to reduce its direct and indirect emissions (Scope 1 and 2) by 33% by 2030. Today, Vale’s rail network represents 10% of the company’s carbon emissions. The initiative is one more step towards achieving the goal of net zero carbon emissions by 2050, in line with the ambition of the Paris Agreement to limit global warming to below 2°C by the end of the century.

The company also committed to reducing its net emissions from its value chain (Scope 3) by 15% by 2035.

Vale and Vivo extend reach of 4G across Carajás Railroad

Vale and Wabtec look to decarbonise Carajás Railroad operations with battery power and ammonia