Intelligent valve maintenance accelerates Mining 4.0 in Brazil.

In a sector responsible for approximately 101% of Brazil's industrial GDP, the challenges of mining go far beyond mineral extraction. Safety, asset reliability, and sustainability have become strategic pillars for the continuity of operations. In this new scenario, the concept of Mining 4.0 is gaining strength, driven by technologies that connect data, automate processes, and enable decisions based on predictability. It is precisely in this context that the maintenance of industrial valves positions itself as an essential agent of transformation.

The role of valves in modern mining.

While barely visible during operation, valves are absolutely critical and responsible for flow control in pipelines. A failure in this component can disrupt the entire production chain, generate losses, and, in extreme cases, cause severe environmental impacts. Therefore, preventive and corrective maintenance of this equipment is becoming increasingly important in asset management strategies.

Anglo American Minério de Ferro Brasil SA has taken a significant step in this direction by signing a contract with FLUXO Soluções Integradas. The objective is to carry out specialized maintenance on valves from ValvTechnologies, the absolute leader in slurry and tailings pipelines in Brazil and worldwide.

“The integrity of our assets is non-negotiable. Preventive and corrective maintenance of critical valves, such as high-pressure and abrasion valves, ensures operational safety and environmental protection. A well-maintained valve is insurance against unexpected failures,” emphasizes Ronan Pereira Cézar, Specialist Engineer at Anglo American.

Maintenance as a sustainability strategy

In the context of Mining 4.0, maintenance has ceased to be a simple repair and has become a way to extend the useful life of assets. This directly impacts the efficiency, costs, and sustainability of the operation. Valve refurbishment using original parts and advanced industrial processes reduces the need for new purchases, prolongs the lifespan of equipment, and prevents the disposal of materials in good condition.

“Valve maintenance is not just a repair, it’s a life extension,” says Fábio André, CEO of FLUXO. “Repairing equipment instead of discarding it reduces the demand for raw materials and waste disposal. With the hardfacing process and original parts, we can guarantee that a refurbished valve achieves up to 70% of the lifespan of a new one, which represents a substantial gain in cost and efficiency,” he adds.

This approach is directly aligned with ESG (environmental, social, and governance) principles, which are increasingly present in investment decisions in the basic industry in Brazil and worldwide.

Mining 4.0: Connected maintenance, more efficient operation

More than a concept, Mining 4.0 is already a reality. It is based on the digital integration of processes, remote and real-time monitoring, predictive maintenance based on historical data, and the use of sensors and automation to increase the efficiency and safety of operations. Instead of acting only after failures, companies act preventively, anticipating risks and optimizing resources.

The contract between Anglo American and FLUXO also paves the way for this new digital era. Continuous valve monitoring, coupled with the digitization of performance history, allows for faster and more accurate decisions. This reduces unexpected failures, increases operational availability, and extends the lifespan of equipment.

Technical knowledge and specialized structure

With over three decades of experience and more than 1,400 valves supplied in Brazil, FLUXO has developed a complete structure to meet the demands of the sector. The company operates with turnkey projects and skilled teams, offering a robust and technically controlled process for the maintenance of industrial valves.

The solution is divided into 4 fundamental steps:

1. Detailed diagnosis and inspection: Disassembly of the equipment, visual and dimensional analysis to identify defects, wear or anomalies.

2. Component recovery: Application of techniques such as sandblasting, machining, welding, and hardfacing to restore critical parts.

3. Assembly and quality testing: Assembly with controlled torque and rigorous pressure and leak testing, following standards such as ASME B16.34 and ANSI FCI 70-2.

4. Certification and traceability: Issuance of a stainless steel identification plate with complete traceability of the service performed, in accordance with ValvTechnologies and customer standards.

Far beyond repair: maintenance as a competitive advantage

What was once seen as an unavoidable cost has now become a tool for competitive advantage. By investing in technology, training, and intelligent maintenance processes, mining companies gain efficiency and position themselves in line with global demands for more sustainable practices.

The journey towards Mining 4.0 demands more refined technical decisions, data-driven asset management, and a strategic vision that values every component of the operation. And, along this path, industrial valves continue to play a central role.