Mining and metals projects in Brazil
AFRY has delivered over 1,000 mining and metals projects in Brazil, covering all stages of the project lifecycle.
- The Alemão Project
- West Zone Program
- TSF Program
- S11D Program
- Additional 40 MTPA – Carajás Mining Complex
- Aripuanã Project
Strengthening the most significant critical minerals supply chain in Brazil
The Alemão Project, owned by Vale S.A. and located in northern Brazil, is considered one of the most relevant mining developments in the country. It stands out as one of the largest underground mines in operation and one of the most significant copper deposits in Brazil. Situated within the Carajás Mineral Province, the project encompasses the extraction and processing of copper ore in a highly complex geological setting with significant metallic potential. Developed under high technical standards, the Alemão Project involves advanced underground engineering solutions, robust mining infrastructure, and stringent operational and environmental safety criteria. It plays a strategic role in Vale’s copper production expansion and in strengthening Brazil’s critical minerals value chain.
The scope of services included Peer Review of Planning and CapEx, as well as Planning Management and Probabilistic Risk Analysis. AFRY also provided comprehensive development of studies, encompassing various necessary disciplines (Engineering, Planning & Control, Construction, Procurement), aiming to enhance planning accuracy, capture opportunities for cost reduction, improve safety, and shorten construction timelines.
Project facts
Client: Vale
Location: Parauapebas, Pará – Brazil
Contract period: November 2022 to December 2023
Earthworks: 8.9 million m³
Electromechanical assembly: 22,000 tons
Concrete: 110,000 m³
Mine development: 36.5 km
Long-term value creation for the mining industry
The West Zone Program (PZO) of Mineração Rio do Norte is a structuring initiative focused on optimizing and standardizing operational processes, with the objective of increasing efficiency, predictability, and control across the production cycle. The program encompasses an integrated analysis of processes, operational routines, interfaces between areas, and performance indicators, promoting technical and managerial adjustments aimed at continuous improvement. PZO is based on the consolidation of more robust operational practices aligned with MRN’s safety, productivity, and sustainability guidelines, directly contributing to long-term operational stability and value generation.
The scope of services included the development of chapters of the Project Execution Plan (PEP) to support the FEL 2 deliverables of the West Zone Program, covering two of its projects. Additional support was provided for defining the procurement strategy, preparing bid documentation, and conducting contracting processes for the PZO service packages, which include the projects PNM02 – New Mines Project, PSR02 – Tailings System Project, and PLT01 – Transmission Line. The scope also included support for the preparation of FEL 3 documentation for two projects within the program, reinforcing the technical partnership, mutual trust, and strategic alignment with the client throughout the entire program development life cycle.
Project facts
Client: Mineração Rio do Norte (MRN)
Location: Pará – Brazil
Contract period: June 2020 to December 2026
Enhancing dam safety with AngloGold Ashanti
The Tailings Storage Facilities (TSF) Program of AngloGold Ashanti in Brazil was conceived in response to the need to adapt tailings dams and other geotechnical structures to the requirements of Brazil’s updated dam safety legislation. The program aims to ensure regulatory compliance, enhance operational safety standards, and reduce risks associated with tailings disposal through the review, reinforcement, and, where applicable, reconfiguration of existing structures. Developed within a context of increased technical and regulatory rigor, the TSF Program represents a structured, long-term initiative to ensure asset integrity, operational continuity, and alignment with national and international best practices in tailings management.
The scope of services included Peer Review of CAPEX, Planning, and Risk Analysis. Full management of the implementation of geotechnical works for AngloGold Ashanti in Brazil, covering four sites: Serra Grande (GO), Queiroz (MG), Córrego do Sítio (MG), and Cuiabá (MG). Activities included Planning, Measurement, Contract Administration, Field Supervision, Quality Management, Economic and Financial Control, and Corporate PMO (project integration). AFRY also provided 4D planning for the Cuiabá dam raising, integrating the schedule with the earthworks model developed in Civil 3D using Navisworks Manage.
Project facts
Client: AngloGold Ashanti
Location: Brazil
Contract period: April 2021 to March 2026
Earthworks:
- Cuiabá: 1.2 million m³
- Córrego do Sítio: 1.5 million m³
- Serra Grande Mine: 2.2 million m³
- Queiroz: 1.0 million m³
Contributing to the largest mining investment in Brazil
Vale’s S11D Program, located in the Carajás Mineral Province in northern Brazil, represents the largest mining investment in the country’s history. With investments of approximately USD 14 billion, the project was executed throughout the 2010s, began operations in 2016, and increased the Northern System’s production capacity by around 90 million tonnes per year of high-grade iron ore. The development includes a mine, processing plant, logistics infrastructure (railway and port), and innovative dry processing systems, significantly reducing water consumption and environmental impacts. It also comprises a robust, integrated logistics infrastructure, including the Carajás Railway (EFC), with approximately 892 km in length, and the Ponta da Madeira Maritime Terminal in Maranhão, responsible for shipping ore to international markets. S11D has become a global benchmark in scale, operational efficiency, technological innovation, and sustainability in mining.
Throughout the development of the works, we supported Vale’s team by providing Integrated Planning Management, covering all implementation packages of the program, including mine, plant, railway, and onshore and offshore port expansion works under Vale’s S11D Program.
Project facts
Client: Vale
Contracting party: Vale
Location: Pará and Maranhão – Brazil
Contract period: August 2013 to April 2015
Concrete: 694,561 m³
Earthworks: 111,387,302 m³
Electromechanical assembly: 261,718 t
Railway: 768 km
Advancing mining technology and sustainability
The Additional 40 MTPA Project, developed by Vale S.A. in the Carajás region of northern Brazil, represents the largest mining investment ever undertaken in the country. Integrated into the S11D Complex, the project was designed to increase the production capacity of the Northern System by approximately 40 million tonnes per year of high-grade iron ore, reinforcing Vale’s leadership in the global market. Implementation took place throughout the 2010s, with commercial operations starting in 2016 and full capacity achieved in subsequent years, establishing the project as a landmark in scale, technology, and sustainability within Brazilian mining.
The scope of services included the provision of specialized services for Project Planning Management of the Additional 40 MTPA Project at the Carajás Mining Complex, Pará.
Project facts
Client: Vale
Contracting party: Vale
Location: Parauapebas, Pará – Brazil
Contract period: January 2013 to September 2013
Concrete: 92,041 m³
Earthworks: 14,167,326 m³
Electromechanical assembly: 45,000 t
Cabling: 1,250,000 m
Diversifying and strengthening base metals mining in Brazil
The Aripuanã Project, located in the municipality of Aripuanã in the state of Mato Grosso and owned by Nexa Resources, represents the largest investment ever made in a polymetallic mining operation in Brazil. With an investment of approximately USD 700 million, the project was developed during the second half of the 2010s, with commercial operations commencing in the early 2020s. The project comprises an underground mine and an industrial complex dedicated to the production of zinc, copper, and lead, with a processing capacity of approximately 4.5 million tonnes of ore per year. Annual production reaches tens of thousands of tonnes of contained metals, with zinc as the primary product, followed by copper and lead. The Aripuanã Project is recognized for its high level of automation, strong environmental performance, and strategic importance in diversifying and strengthening Brazil’s base metals mining sector.
The scope of services included Engineering consultancy and specialized services for the development of the Project Implementation Plan (PIP).
Project facts
Client: Nexa Resources
Contracting party: Nexa Resources
Location: Aripuanã, Mato Grosso – Brazil
Contract period: April 2018 to October 2022
Concrete: 15,000 m³
Equipment assembly: 3,500 t
Steel structures: 3,000 t
Piping: 900 t
Cabling: 270 km
