843 CONCLUSIONS The Clarabelle Mill reliability and efficiency improvement transformation is progressing well. A key catalyst for this advancement has been the SAG liner failure event, consequently the liner design optimization, and the implementation of a revised SAG mill reline strategy. • Worker safety risk for SAG entry was significantly reduced with the elimination of packing and pegging between the liners; risk of falling material from the liners was eliminated. • Clarabelle SAG mill availability increased by 2%, driven by successfully implementing the new SAG reline strategy, resulting in a reduction from 4 to 2 relines per year. • SAG mill high wear reline downtime decreased 25 hours as a result of the new liner configuration, which decreased the total number of shell liner pieces by 100. • Unplanned SAG mill liners downtime was mitigated by the elimination of chronic liner failure events through improved reliability-centered liner design and condition-based monitoring practices • Unscheduled shutdown due to broken bolts were mitigated via the optimization of bolting procedure, lubrication and implementation of smart bolt technology that enables real-time tension monitoring • Grinding efficiency was significantly improved, resulting in a throughput increase of 66 tons/hour and a 7% reduction in specific energy consumption FURTHER TRANSFORMATION In 2026, in alignment with the SAG reline strategy roadmap focused on improving mill availability, a new iteration of this Hi-Hi shell liner design will be evaluated to achieve its full wear life potential. This trial will support ongoing continuous improvement initiatives and determine the feasibility of transitioning to a Hi-Lo liner configuration for future installs (long-term objective of achieving 1 SAG reline per year). ACKNOWLEDGE The authors acknowledge Vale’s Clarabelle Mill for permission to publish this paper. Also, Kaltech, Russel Mineral Equipment, Copper State Bolts, Unmanned Aerial Inc. for their support on SAG reline strategy REFERENCES Breininger, R. (2025). Clarabelle SAG Mill Bolting Report – LMF+ Installation Report, Copper State Bolt and Nut / BoltSense LMF+ Helluin, G. (2025). Clarabelle SAG Mill Drone-UT Inspection Report, Unmanned Aerial Services Inc. Jansch, J., Birkhofer, H. (2006). The Development of The Guideline VDI 2221 – The Change Direction, International Design Conference – Design 2006 Orcon, N. (2022). Root Cause Analysis – SAG Shell Liner Failure, Clarabelle Mill Reliability Engineering Orcon, N. (2023). Study of Shell Liner Wear Profile, Clarabelle Mill Reliability Engineering Outkes, C. (2025). Clarabelle Mill SAG Mill Reline Service Report, Kaltech Powel, M., Smit, I., Radziszewski, P., Cleary, P., Rattray, B., Eriksson, K., Schaeffer, L (2006) The Selection
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