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By A. S. Ericson, J. H. Corrigan, E. J. Jahnsen

Calcine is transported from the Reduction Plant at 850°C in insulated hopper cars and charged into three rectangular electric melting furnaces each equipped with three - 18.5 MVA transformers. The electrical energy is applied through six in line prebaked carbon electrodes, and slag and metal are tapped at opposite ends of the furnaces on an intermittent basis. The slag, 5000 tonnes per day, is disposed of by a pot train directly to the dump. The ferronickel, 250 tonnes per day, is tapped into 40 tonne capacity ladles in which it is refined in two ASEA-SKF ladle furnace stations. Casting is done over lip at 1520°C in a pig casting machine with stepless speed control at up to 55 tonnes per hour. The ingots are stacked into self palletizing bundles weighing about 1500 kilograms and are strapped and tagged and transported to the seaport, from which the final shipment is made to the world market. The paper describes constructional details and gives information of both normal operation and start-up and shut-down procedures. Consumption figures for refractory, electrodes, electric energy and refining additions are given and metal chemistry is given before and after refining.

Jan 1, 1979

By Lionel Ryan

In 1996, the Dominican Republic operation of Falconbridge (Falcondo) developed a 5-year Process Control Plan in conjunction with the corporate Process Control group located in Sudbury, Ontario, Canada. This plan was further refined into an analysis of the areas of the highest potential economic return for the company with the reduction shaft furnace operation being the most promising. Historically, the reduction plant, which comprises 12 shaft furnaces, has been the bottleneck of ferronickel production. Since 1996 there has been a history of control development, and the current status is that all 12 furnaces are using advanced model-based multi- variable predictive control. The combination of advanced process control (APC), improved control system performance and improved process information management has resulted in an increased throughput of 6% per shaft furnace and a reduction in operating costs of 4.5 US cent/lb of Ni. This paper reviews some of the major milestones that have been achieved in this development Keywords: Advanced Process Control; Model Based Predictive Control; Connoisseur, Reduction Shatt Furnace; Nickel Laterite Ore; Ferronickel; MonitorMV

Jan 1, 2004

By Peter Wells, Gordon Marrs, Dominic Fragomeni, Warren Holmes, Daryl Macnamara

"LocationThe Strathcona mill ofFalconbridge Limited is located in Onaping, Ontario, 50 km northwest of Sudbury.GeneralOre from the Falconbridge mines in the Sudbury Basin (Strathcona, Fraser, Onaping, Craig and Thayer Lindsley mines) is processed through the Strathcona mill with 8500 t of nickel ore and 1500 t of copper ore being treated daily. Current capacity is -3 Mt of ore at 1.8% Ni, 1.9% Cu combined grade. Custom feeds are also processed. The valuable minerals in the ore are pentlandite (FeNi)9S8, chalcopyrite (CuFeS2) with some cubanite (CuFe2S3) and very minor nickel sulphides/ arsenides. Cobalt is present mainly in solid solution in pentlandite. There are small but economically important concentrations of precious metals including platinum, palladium gold, and silver. The common non-sulphide gangue minerals are feldspar, quartz, mica, talc, and chlorite while pyrrhotite (Fe7S8) is the major gangue sulphide. The pyrrhotite contains between 0.6% and 1.2% nickel in solid solution and additional nickel as exsolved pentlandite in micron sized blebs. The nickel and copper ores are batch-crushed in a two stage dry crushing plant and then ground in separate circuits. Concentration by flotation and magnetic separation produces a nickel concentrate assaying approximately 16% nickel plus copper and a copper concentrate assaying 30% copper and 0.4% nickel. The nickel concentrate is trucked as a slurry to the Falconbridge smelter while the copper concentrate is trucked as filter cake to the Kidd Division of Falcon bridge"

Jan 1, 2000

By Gerald A. Crawford

"1880s - Unmasking the Sudbury Basin Falconbridge Ltd. turned 60 in 1988 but its roots go back more than a century to the discovery and development of the mineral resources of the Sudbury Basin. Nickel was first identified in the area in 1856 but sustained exploration awaited the early 1880s and the advance of the CPR westward from Sudbury. Rock was laid bare in the right-of-way and by forest fires and logging. Reddish oxidized outcropping or ""gossan"" were exposed, heralding the presence of nickel as the shape of this astounding geological formation gradually began to emerge. Many great mines of the area were opened up in this period on the south rim of the Basin west of Sudbury. To the east the ore dips below overburden, however, and Falconbridge remained a mere dot on the map until the turn of the century when Thomas Edison detected a magnetic occurrence by dip needle."

Jan 1, 1999

By V I. McCallum

In 1954, Falconbridge Nickel Mines Limited began the program of deepening the Falconbridge mine workings for 2,000 feet below the bottom, or 4025, level in order to provide twelve new levels for production. Involved in this program were a production-sized internal shaft, .crushing, pumping and hoisting installations, the integration of the new shaft operations with those of existing shafts, and considerations of ventilation requirements and ground support at depth. This paper describes the major items of equipment, and the depth development of No. 9 shaft as a whole, and also emphasize the planning phases of the program. The factors involved and reasons for the equipment and layouts chosen are given. Introduction and History THIS paper describes the planning and development of that portion of the Falconbridge mine between the 4025 and 6050 mining levels. This mine, the oldest of several being operated by Falcon-bridge Nickel Mines Limited in the Sudbury district, has been a continuous producer for over thirty years.

Jan 1, 1964

Falconbridge Nickel, the one-time subsidiary that grew up to swallow its own parent, Ventures Limited, in 1962, is not about to be left behind by rising nickel consumption. At a cost of several hundred million dollars, this Canadian firm has undertaken a series of new projects that will not only ensure its present share of the market, but also lead it into new areas of the nickel business. Although Falconbridge Nickel Mines Ltd. was not formed until 1928, it actually had its start in 1917- 18 with the discovery of a large, good grade nickel- copper deposit in Falconbridge, near Sudbury, Ontario. However, due to several factors, financing could not be obtained and the orebody lay fallow. It was not until 1928, when the Thayer Lindsley interests bought the property from the original owner, that it was developed.

Jan 10, 1968

By G. E. Norman, J. F. Jackson, A. L. Mckague

"The treatment of nickel-copper concentrate in the new smelter at Falconbridge Nickel Mines Limited, Falconbridge, Ontario, is described. The concentrate in a slurry form is partially roasted in a fluid-bed roaster and the calcine is smelted in an electric furnace. The roaster gases are treated in an acid plant. IntroductionSmelting began at Falconbridge in 1930 with the first blast furnace treating high-grade ore containing 2-3% nickel. In 1933, the Falconbridge concentrator was built and started producing a bulk sulphide concentrate containing 4% nickel. A sinter plant was built to agglomerate and partially roast this concentrate. The sinter was smelted in blast furnaces along with high. grade magnetic ore. Matte from the furnaces was treated in Pierce-Smith converters to produce shipping matte which was refined at the company's plant in Norway."

Jan 1, 1980

By H. H. Bird

Kilembe is situated in the foothills of the Ruwenzori Mountains in Uganda. Precambrian stratiform copper de-posits are currently being mined at a rate of 90,000 tons per month. Complex ore structures and variable ground conditions have led to diverse mining methods in the past. New mining areas contain more shallow-dipping, highly contorted orebodies, in heavy ground. Cut-and-fill mining will be practised in the future. The geology, mining and milling are described.

Jan 1, 1968

By Lloyd F. Dunham

"Crucial to the implementation of new computer-based information systems at Sudbury Operations of Falconbridge Limited was a data communications network that would take computing power to the various mine and plant sites. Falconbridge required a capability to provide on-line data entry, inquiry, and reporting capabilities in three geographical areas, six mines, two mills, a smelter, approximately fifty shops, seven warehouses and numerous administrative offices throughout the Sudbury basin.Conventional cabling methods were rejected based on the projected cost of installation of necessary cables; lack of flexibility to meet the changing requirements of the mine environment; and the risk of losing service to an entire area depending on solitary communication lines.Instead, Falconbridge selected and installed a Data Carrier System (DCS) and Packet Switching Communication System from Teltone Limited, Markham, Ontario. This combined system ""piggy-backs"" computer data over voice-grade twisted pair wire, bringing data to the associated PBX equipment. From there data packets are assembled and routed to the central computer site where they are disassembled for entry into the host machine.Falconbridge has been successful in using existing technology to solve communications problems in a difficult environment. Plans for the future of this network will increase its utilization for technical and real time data communications in addition to the business systems workload it now handles. The Computer Services group in Sudbury is confident that the data highway will handle communications traffic well into the future.IntroductionIn late 1984, the Sudbury Operations of Falconbridge Limited undertook a review of their existing business computer systems. The results of this review indicated that there was an opportunity to improve the timeliness and quality of information coming from the existing computer-based systems while achieving an investment payback by undertaking the project. The greatest benefits from this project would be achieved if the computing tools could be delivered to the employees that were the day-to-day users of the data. Falconbridge's existing business systems were oriented to the batch mode of processing. An alternative solution to using the existing programs had to be found."

Jan 1, 1988

By D. B. Hyma

"The Raglan Ni/Cu property is located on the Ungava Peninsula in Northern Quebec, Canada, at a latitude of61°42' and a longitude of73°40', approximately 40 km southwest of Douglas Harbor. Geological reserves are estimated at 18 million tonnes, grading 3. 1 % nickel, 0.9% copper and smaller amounts of cobalt and platinum group metals.Extensive project development has defined the concentration process, concentrator sizing, tailings and environmental management required for this project.The grinding circuit selected is a fully autogenous primary grind, with pebble crushing and a pebble mill for secondary grinding to produce a product of 80% -70 microns for flotation.The flotation circuit is a simple circuit utilizing roughing, a regrind of rougher concentrate to 80% -20 microns, two stages of column cleaning with a cleaner scavenger bank on the column tails.Concentrate handling options were thoroughly reviewed because of the pyrophoric nature of the concentrate, remote site location and long distance to downstream processing. The preferred option, currently.is to dry the concentrate at Raglan to less than l % moisture and then pneumatically handle the powder.A detailed analysis of tailings placement options, suggests filtered tailings placement to be the preferable route for the Raglan site.INTRODUCTIONThe Raglan Project, as proposed by Falconbridge Limited, will develop extensive nickel-copper deposits in the Ungava Peninsula, Quebec, Canada. The project schedule and construction conditions in the project area are demanding. The Raglan mineral deposits have been the subject of numerous studies and evaluations over the last thirty years and the Phase I 1991 pre-feasibility document includes exploration information obtained in the 1989 and 1990 drilling seasons. This review concluded that an 800,000 tonnes of ore per year mining and concentrating complex located at Katinniq could produce 20,000 tonnes per year of nickel at competitive costs."

Jan 1, 1993

By Edwin de Jesús Deveaux

After 32 years of operations beneficiating lateritic nickel ore in a fully integrated pyrometallurgical complex, Falconbridge Dominicana (FALCONDO), situated at Bonao and La Vega Provinces, Dominican Republic, has become profitable with one of the lowest nickel grade content processing plants in the world, and literally without any by-product (granulated slag, will be utilized in the future as a post-processing subproduct). To December 2002, mineral reserves were 64.1 million tonnes containing laterite grading as low as 1.15 % Ni when full dilution is applied. At a cut-off grade of 1.20% Ni, the reserves will provide 15-20 years of production. The mineralized thickness over the seven active deposits averages 6 m. Development of very selective and unique mining practices, together with improvements in the process plant, are key to achieving the production goal (30 kt Ni/yr) and to meet the quality standards for the ferronickel produced. Keywords: Laterites, grade control, mining methods, environment

Jan 1, 2004

By Susan M. Moore

The objective of this study was to evaluate the circumstances leading to fall from equipment injuries in the mining industry. Method: The 2006 and 2007 Mine Safety and Health Administration annual injury databases were utilized for this study whereby the injury narrative, nature of injury, body part injured, mine type, age at injury, and days lost were evaluated for each injury. Results: The majority of injuries occurred at surface mining facilities (~60%) with fractures and sprains/strains being the most common injuries occurring to the major joints of the body. Nearly 50% of injuries occurred during ingress/egress, predominately during egress, and approximately 25% of injuries occurred during maintenance tasks. The majority of injuries occurred in relation to large trucks, wheel loaders, dozers, and conveyors/belts. The severity of injury was independent of age and the median days lost was seven days; however, there was a large range in severity. Impact on industry: From the data obtained in this study, several different research areas have been identified for future work, which include balance and stability control when descending ladders and equipment design for maintenance tasks.

Jan 1, 2009

By AIME AIME

SECOND only to the February Annual Meeting of the Institute are the Regional and Divisional meetings held in the fall of each year. Six such gatherings are scheduled in the next the months, with something likely to interest every member of the Institute. A brief résumé of the programs follows. Regional Meeting Vancouver T HE regional meeting of the Institute will be held at Vancouver, Sept. 13 to 20, in conjunction with the annual western meeting of the Canadian Institute of Mining and Metallurgy. The pro gram appeared on page 350 of MINING AND METALLURGY for July and-proof of careful preparation-a month later re- quires no correction and little elaboration. On the technical side there are few changes. A new item on the Wednesday morning program is the paper, "Investigation of Residential-type Stokers," by H. F. Yancey, supervising engineer, Northwest Experiment Station. U. S. Bureau of Mines, Seattle. As to entertainment the meeting is taking on some most pleasurable aspects. Two notable excursions have been arranged.

Jan 1, 1937

TULSA, the host of the Petroleum Division this year, is the oil metropolis of the Mid- Continent and gateway of the Southwest. It has risen in less than three decades from a dusty cattle town of less than 1000 population to its present-day status of a modern, wide-awake and prosperous city of close to 150,000, with an assessed realty valuation of approximately $100,000,000. Oil was discovered near Tulsa in 1901, and with it came th.2 development of the Mid-Continent field, one of the richest in the world. Tulsa from the start has been the center of operations, and its location on foul- and aggressive application of the airplane to oil-field requirements tends to fix this status as production is developed farther and farther afield. That Tulsa is far more than an ephemeral oil town is punched into the newcomer's- especially the Easterner's-mind, as he is whisked by taxi from the railroad station to the Hotel Mayo. The cicadalike pounding of the riveters on the steel skeletons of many skyscrapers, mounting upward to fill the gaps in an already well-developed skyline, dispels the feeling of a new atmosphere and puts him back on Forty-second Street, Michigan Boulevard or whatever his own particular "Main Street" may be along which an American city is being remade. Practically every company of any importance operating in the Mid-Con-

Jan 1, 1928

By AIME AIME

A THOROUGHLY satisfactory crowd turned out at the fall meeting of the Industrial Minerals Division and took an active part in the entire program. On Thursday afternoon, Sept. 24, a limestone plant was inspected, technical sessions occupying the attention of the visitors all day Friday and Saturday morning. Headquarters were at the Nittany Lion Inn, an attractive hostel on the Penn State campus, at State College, right in the center of Pennsylvania. We are still in the dark, despite inquiries, as to just what breed of lions Nittany lions are. As nearly as we could find out, Nittany is not a Biblical name, as it sounded to us, but a corruption of the name of an Indian princess, or maiden, or maybe just girl that haunted those parts in bygone times and after whom a near-by mountain was named. Penn State athletes are "lions" and there you are. The meeting was supposed to be a joint one with the American Ceramic Society's Materials and Equipment Division; but it was quite evident that the Institute had a much better publicity agent than the Society, which bothered Ross. Purdy, the aggressive secretary of the ceramic people, no end. However, Secretary Purdy saw to it that everyone present fully understood that the Ceramic Society was present, so that that contingent all but stole the show, its representatives presiding at every meeting. The Pittsburgh Section of the American Ceramic Society was also supposed to be holding its fall meeting there at the same time, but made no trouble at all for anybody, as one of the speakers remarked.

Jan 1, 1936

By AIME AIME

OCTOBER will be western month for the Institute. With meetings at Spokane, Tulsa, Los Angeles, and San Francisco, and with a large number of American Institute of Mining Engineers members and their families in the party sailing out through the Golden Gate to Japan on the afternoon of the tenth, the major activities of the Institute will, for this month at least, be west of the Mississippi. Despite cancellations due to necessity, most of the officers of the Institute will be present and taking part in some one or more of the Western meetings. Prof. Robert S. Richards, our senior past-president, will attend both the Spokane and San Francisco meetings and then go to Japan. President Bradley will preside at the San Francisco meeting and then head the party going to Tokyo. At Tulsa and Los Angeles, the principal officers of the Petroleum Division will be present and active and at all the meetings, directors, ex-directors and -present and past officers will be on the job and keeping things moving.

Jan 1, 1929

By G. E. Walker

"El Manto Ombla en Morococha, ha producido cobre durante más de 30 años. Cuando esta producción llega a su etapa final, se decidió hacer una investigación y descartar evidencia de otro mineral existente. Por ello, el texto señala los resultados de este estudio, como los conceptos nuevos sobre la geología. La mineralización de este manto no constituye un reemplazarriento selectivo, sino más bien fue controlado por una falla de compresión, cuyo producto estriba en la compresión lateral, plegamiento asimétrico y décollement. El fallamiento de compresión se extendió oblicuamente a través de los horizontes incompetentes formando una traza característica en ""S"", paralela al plano axial origina del pliegue asimétrico, y eventualmente se unió al plano basal de desprendimiento en el contacto volcánico. Dicha mineralización se inició con una etapa con una fase pirítica que formó reemplazamiento masivo a lo largo del contacto volcánico y penetró también los horizontes de anhidrita a lo largo de ciertas fracturas. Así, la anhidrita no parece haber causado la disminución de la mineralización en profundidadexcepto en el sentido de haber restringido la migración de las soluciones mineralizantes. "

Aug 20, 1963

By Ramsden AR, French DH

The limited contrast range of conventional black and white imaging does not enable full use to be made of the dynamic range of the video signal obtained from a scanning electron microscope or microprobe. The use of false colour substantially increases the information that can be derived from such images enabling relationships to be displayed that cannot be observed in black and white. This capability is now used extensively in combination with quantitative electron microprobe analysis as a research tool for ore characterization and host rocks studies related to minerals exploration in the CSIRO Division of Exploration Geoscience.

Jan 1, 1989

By G. A. Gamble

"The inlet air velocity profile of any surface mine ventilation fan is an important factor when designing the connecting ductwork from the mine shaft collar to the fan. Deficient fan performance can be the result of ductwork that adds unnecessary pressure loss and/or adversely influences the fan inlet air conditions (velocity profile). The need for optimized inlet air conditions begins with discussing the process of performance testing during the development of the fan performance curve. Additional discussions include design of the shaft collar connection and the connecting ductwork. A preferred design of ductwork for parallel fan installations will be illustrated.INTRODUCTIONThe inlet air velocity profile of any surface installed mine ventilation fan is one of the most important factors to consider when designing the connecting ductwork from the mine shaft collar to the fan. Oftentimes deficient fan performance can be traced to poorly designed ductwork that adds unnecessary pressure loss and/or adversely influences the fan inlet air conditions (velocity profile). Such designs may lead to added power requirement, excessive vibration and noise, and reduced fan performance.Understanding the need for optimized inlet air conditions begins with discussing the process utilized when factory testing takes place during the development of the fan performance curve.Additional discussions include design considerations for the shaft collar connection, the connecting ductwork, and fan inlet. Illustrations of cost savings and pressure losses will be included for audience consideration. The design of ductwork for parallel fan installations on the surface is another issue that requires consideration. A preferred method will be illustrated.The selection of accessory components, such as self-closing doors, can also add to the potential for reduced fan performance. Several components will be discussed.An elementary presentation of the Air Movement and Control Association (AMCA) Standard 201 “Fans and Systems” will be included to provide background for those audience members that want additional technical explanations of the need for a uniform inlet air velocity profile at the fan inlet."

Jan 1, 2019

By D Chalmers

"There is a tendency to treat mine roadways with fan installations as leak proof systems. Morecomplex ventilation arrangements are being installed in coal mines out of necessity or designand these can introduce additional hazards. This paper explores the leakage paths that can existaround fans and in particular the hazards these leakage paths may generate around undergroundfan installations. The behaviour or these leakage paths in the event of a fan failure has also beenexplored. Early detection of spontaneous combustion is essential, so understanding the leakage behaviour around fans especially boosters or main fans installed underground will assist in sett ing up monitoring locations in the correct places. If this behaviour is not fully understood then monitoring may be placed incorrectly, or trends may not be picked up until it is too late."

Jun 1, 2012