Gyratory Roller Solutions (GRolls®) is revolutionising mineral processing with an innovative comminution technology that reduces energy consumption, water usage, and operational costs. By applying a unique combination of shear, tension, and compression forces, GRolls® delivers a more efficient and sustainable alternative to traditional grinding methods, supporting the mining industry's transition towards lower-emission and cost-effective operations.

Gyratory Roller Solutions: Revolutionising Comminution for a More Sustainable Mining Industry

Tackling Energy and Cost Challenges in Mineral Processing

Mining operations are essential for extracting valuable resources, but the process is highly energy-intensive, particularly in comminution—breaking down large rocks into smaller ones for mineral extraction. Comminution circuits account for over 1% of global energy consumption, with some mining operations dedicating up to 80% of their total electricity use to this process. Additionally, the reliance on grinding media and water contributes to significant operational costs and environmental impact.

Gyratory Roller Solutions Pty Ltd (GRolls®), founded in 2023 in Adelaide, aims to transform this landscape by developing innovative, efficient, and modularised comminution technology. By reducing energy, media, and water requirements while maintaining or improving mineral recovery, GRolls® technology supports industry goals of lowering greenhouse gas emissions, reducing water consumption, and improving the economic viability of lower-grade more complex ore bodies in remote locations.

A Breakthrough in Comminution Technology

GRolls® introduces a patented crushing design that applies energy-efficient shear, tension, and compression forces simultaneously to process feed material more efficiently. Unlike traditional comminution methods that rely on attrition (SAG and Ball mills) or high compressive loads(HPGRs or VRMs), GRolls® forces generate fine particles with fewer re-circulations, reducing energy consumption and eliminating the need for grinding media and excessive water usage.

This innovation positions GRolls® as an ideal replacement for secondary grinding applications using ball mills, achieving the same particle size output with greater efficiency and no media. Additionally, the combination of compression, tension, and shear forces results in lower stress on structural components, allowing GRolls® units to be lighter, smaller and suit modular applications. The technology can also process wet feed materials more effectively, making it a flexible solution for various mining environments.

GRolls® is designed to integrate seamlessly into existing comminution circuits, either as a supplementary unit to enhance productivity or as a replacement for older, less efficient equipment. With a compact, modular design, GRolls® is well-suited for new mine developments, mine expansions, satellite deposits, and even tailings reprocessing.

Leadership and Research-Driven Innovation

The development of GRolls® in South Australia is led by Mark Drechsler, a passionate engineering geologist with over 40 years of experience in the mining and infrastructure sectors. As a founder of CBSM in 2018, Mark played a pivotal role in developing and testing the GRolls® technology and is currently undertaking a PhD at the University of South Australia, further advancing research into the energy and mineral processing benefits of GRolls®. His work has attracted engagement from multiple mining companies eager to provide feed materials for research trials.

Pioneering the Future of Sustainable Mining

With the mining industry facing increasing pressure to reduce environmental impact while improving efficiency, GRolls® presents a game-changing solution. By significantly cutting energy use, water consumption, and operational costs, the company is setting a new standard for comminution technology.

As the industry moves towards net-zero targets by 2050, Gyratory Roller Solutions is poised to play a key role in ensuring that mining industry remains economically viable, environmentally responsible, and ready to meet the demands of the future.