How Sustainable Tech Could cut Mining's Energy use

The mining sector is experiencing unprecedented demand for critical minerals as global industries accelerate their transition to renewable energy. However, this surge in activity has brought heightened scrutiny over environmental impact, forcing mining companies to confront the carbon-intensive nature of their operations. In response, the industry is turning to innovative technologies that could simultaneously reduce emissions and improve operational efficiency.

Among these developments, a South Australian company called Gyratory Roller Solutions (GRolls) is pioneering crushing technology that could reshape how the sector approaches one of its most energy-intensive processes.

Researchers at Adelaide University are investigating the technology, which early findings suggest could offer substantial environmental and economic advantages over conventional methods.

The push for sustainable mining has intensified as critical minerals become central to clean energy infrastructure, electric vehicles and national security priorities. Whilst definitions vary by region, materials including copper, cobalt, lithium and aluminium are recognised as essential commodities globally.

Copper, in particular, is increasingly classified as critical due to its vital role in the energy transition, yet extracting it remains expensive, time-consuming and emissions-heavy. GRolls' technology addresses one of mining's most problematic processes: comminution.

This essential procedure involves crushing and grinding ore to separate valuable minerals from waste rock. According to Mark Drechsler, GRolls Director and Adelaide University PhD candidate, the company's innovation significantly reduces the need for traditional grinding and milling operations when processing copper and gold ore.

The environmental implications could be substantial, as Mark notes that the technology has the potential to dramatically lower both operating costs and the sector's carbon footprint.

Tackling mining's energy challenge

The scale of energy consumption in ore processing is staggering. Mark explains that ore crushing and grinding traditionally represent one of the most energy-intensive processes in mining, accounting for more than 1% of global energy use and up to 80% of a mine's site power consumption.

This makes comminution a prime target for sustainability improvements across the industry. GRolls' approach combines pulsed compression, tension and shear forces to break down ore more efficiently.

In a single pass, this combination of processes reduces more than 40% of particles to less than 425 microns whilst generating less than 14% of fine particles smaller than 75 microns. The technology shows particular promise when processing finer ore feeds under 2.36mm.

The innovative method represents a significant departure from traditional comminution approaches. By targeting the most energy-intensive aspect of mineral processing, the technology addresses a critical bottleneck in sustainable mining operations.

Proven results in real-world testing

Testing of the GRolls circuit at a copper-gold operation in New South Wales (NSW) has provided compelling evidence of its potential. When compared against traditional grinding operations, the technology demonstrated a 20% reduction in energy consumption whilst nearly halving total comminution costs.

Mark notes that these savings extend beyond power consumption: "Not only do you reduce power use, but you eliminate the cost of grinding minerals. There are also potential savings in water usage and a reduction in greenhouse gas emissions."

These results could prove increasingly valuable as the mining industry faces mounting challenges. Ore deposits are becoming more complex and remote whilst ore grades continue to decline, making efficiency improvements essential for economic viability and environmental responsibility.

Dr George Abaka-Wood, Future Industries Institute metallurgist and supervisor of the GRolls project, emphasises the broader implications: "The team is committed to showing the downstream benefits of using dry crushing technology in collaboration with other innovative technologies to address the need for more energy-efficient and higher processing efficiencies within mineral processing flowsheets." Dr Abaka-Wood's research highlights the potential for integration with emerging processing technologies.

A flexible solution for widespread adoption

The compact yet scalable nature of GRolls' technology could facilitate its adoption across diverse mining operations. The system can function as a standalone unit or be integrated into existing circuits, operating in either dry or wet conditions.

This flexibility could prove crucial for an industry with varied operational requirements and infrastructure constraints. The modular design allows mining operations to implement the technology without wholesale replacement of existing infrastructure.

Professor Bill Skinner, co-author of the study and Research Leader of Minerals and Resource Engineering at the Future Industries Institute, views the technology as transformative: "It offers an opportunity to simplify processing circuits while improving sustainability across the board." Professor Skinner's assessment underscores the technology's potential industry-wide impact.

GRolls plans to commercialise the technology in 2025, supported by an AU$300,000 (US$211,400) South Australian Government Seed-Start grant. If successfully scaled and deployed commercially, the innovation could establish new benchmarks for sustainable minerals processing across the global mining sector.