About Us
From 2022 to 2023, Brian Gerrell served as the Principal Net Zero Program Engineer at Rio Tinto's Energy & Climate Change Centre of Excellence in Melbourne, Victoria. In this capacity, he demonstrated significant leadership and technical expertise, successfully delivering ten Net Zero Pathways Options Studies for operating sites and three major expansion projects over an 18-month period. These studies adhered to required standards, providing a deeper understanding of corporate sustainability goals and optimising operational decarbonisation pathways to maximise decarbonisation impact while minimising capital expenditure.
He engaged extensively with senior leaders across product groups and internally within the organization, developing the Net Zero Pathways program from a conceptual planning stage into an effective business management tool. This included a technology demonstrator application for the Iron Ore Group value chain.
In this role, Brian was responsible for leading and technically supporting technology options engineering studies, developing integrated plans to achieve designated value chain decarbonisation goals, and advising on technical and commercial aspects to prioritize investments in decarbonisation. He was tasked with integrating Net Zero pathways into operational planning cycles, promoting teamwork and engagement among Climate Leads and technical experts across Rio Tinto's various groups, and incorporating Net Zero Pathways as a standard part of operations.
From 2017 to 2022, Brian held the position of Principal Advisor for Flowsheet Development at Rio Tinto Development and Technology in Bundoora, Victoria. During this time, he led the team in producing a trade-off study model that facilitated financial comparisons between two different recovery flowsheets, enabling strong investment decisions. His expertise in flowsheet and engineering support benefitted over twenty project teams, leading to cost-optimal flowsheet and technology changes that promoted project viability. He also oversaw the design, manufacture, and supervision of a pilot plant program for innovative technology to recover organic contaminants from Bayer Liquor. This program validated the design and identified essential parameters for full-scale engineering and construction. His responsibilities included managing engineering companies to produce trade-off studies, generating flowsheets for new deposits, functioning as a Subject Matter Expert (SME) in flowsheet design, and developing processing test work and pilot plant programs to increase operating profits for existing operations.
In 2016 and 2017, as Program Lead for Organics and Silica at Rio Tinto Aluminium in Brisbane, Queensland, Brian was granted a patent for a novel flowsheet that enabled the recovery and sale of fine bauxite from the Andoom tailings facility, turning waste material into revenue. He successfully coordinated a consensus among SMEs on utilising existing technologies to remove oxalate and silica from Bayer liquor, leading to robust business cases that continue to support research expenditure. His responsibilities involved developing Bayer Liquor impurity management techniques to increase profitability and creating methods to generate additional revenue from the aluminium value chain.
Between 2010 and 2015, Brian Gerrell served as Principal Advisor for Process Development at Rio Tinto Technology and Innovation in Bundoora, Victoria. In this role, he generated flowsheets for more than ten projects, maximising business value and facilitating due diligence reviews for both greenfield and brownfield development opportunities. He initiated, designed, and developed an order of magnitude study into recovering rare earth elements at Rio Tinto operations, incorporating metallurgical/chemical test work and full engineering of a novel process. This study presented senior management with a technically proficient and economically viable option for further development. As a process design SME, Brian provided expert flowsheet and engineering support to project teams, designed and developed processing test work programs and pilot plant programs, and supported efforts to increase efficiencies and operating profits for existing operations.
From 2007 to 2010, Brian was the Manager of Innovation at Rössing Uranium Limited, a Rio Tinto-owned company in Namibia. He conceived, designed, constructed, and operated test columns and a full pilot plant for a uranium heap leach operation, generating a conceptual flowsheet to recover valuable byproducts from the orebody. Brian also established the Innovation Team from scratch, including recruitment, training, and standards development. His responsibilities included setting up and operating the uranium heap leach testing program and valorising by-products from the Rössing orebody
From 2005 to 2007, Brian held the role of Manager of Processing at Rössing Uranium Limited in Namibia. Under his leadership, the Processing Plant surpassed metal recovery targets sustainably for the first time in over a decade. He identified and addressed safety concerns related to the construction and operation of the Tailings Storage Facility, preventing multiple fatalities. He led the reorganisation of the Processing Department, resulting in improved control of standards, better communication, and faster decision-making. His responsibilities encompassed full operating and maintenance management for all processing operations, including support functions, tailings disposal, and water management. He managed a team of over three hundred people, including contractors, with nine direct reports, and had full responsibility for health, safety, environment, and quality aspects of processing operations. During his tenure, the Rössing processing operations achieved and maintained ISO 9001 certification.
Additionally, he was responsible for generating and managing the Processing Plant budget, including major capital expenditure, and producing annual performance, environmental, and health and safety reports for the Rössing Uranium Limited board, and the national regulators. Throughout his career at Rio Tinto, Brian demonstrated exceptional leadership, technical expertise, and a commitment to sustainability and innovation. His contributions significantly advanced the company's decarbonisation efforts, optimised operational processes, and enhanced overall profitability.
Brian Gerrell’s
skills and expertise
Sustainability and Decarbonisation:
Comprehensive understanding of corporate sustainability goals and strategies for operational decarbonisation.
Expertise in advising on technical and commercial aspects of decarbonisation, prioritizing investments to maximise impact and minimise costs.
Technical Expertise:
Deep technical knowledge in developing and delivering Net Zero Pathways and decarbonisation projects.
Extensive experience in flowsheet development, including generating and optimising recovery flowsheets for various projects and commodities.
Expertise in designing, developing, and supervising pilot plant programs and processing test work.
Project Management:
Proficiency in leading complex engineering studies, developing integrated plans, and managing trade-off studies
Skilled in prioritizing investments, maximising project viability, and integrating decarbonisation pathways into operational planning cycles.
Innovation and Problem-Solving:
Ability to conceive, design, and implement innovative technologies and processes, such as novel flowsheets and recovery methods.
Successfully addressed and resolved critical safety and operational issues, improving both safety standards and operational efficiency.
Stakeholder Engagement:
Experience in engaging with senior leaders and internal stakeholders to develop and implement strategic programs.
Proven ability to coordinate and achieve consensus among subject matter experts, ensuring robust business cases and sustained research expenditure
Regulatory and Standards Compliance:
Experience in maintaining compliance with health, safety, environmental, and quality standards, including achieving ISO 9001 certification.
Skilled in generating detailed reports for regulatory bodies and company boards, covering performance, environmental, health, and safety aspects.
Leadership and Management:
Demonstrated ability to lead and manage teams, as evidenced by his roles as Principal Net Zero Program Engineer, Principal Advisor, Manager of Innovation, and Manager of Processing
Proven track record in establishing and coordinating forums and teams, fostering effective communication, and driving coherence among diverse groups.
Experience in managing large teams, including direct reports and contractors, while overseeing extensive operational responsibilities.
Financial Acumen:
Competence in managing budgets, including major capital expenditure, and facilitating financial comparisons for investment decisions.
Experience in generating additional revenue through innovative recovery processes and by-product valorisation.