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ORGANIZATION

and KQUIPMKNT

THE CANADIAN
COPPER COMPANY

ALEXANDER GRAY

In The MINING WORLD. Chicago

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The Canadian Copper Co.

CIIAPTKR I.

INCKI'TIO.V AMI OHC.ANIZATKIN.

Romantic stories of discovcrirH iind (Kvclopniciit in nu-tal niiniuK tinvi- no more
instructively intercstitiK, tliniiKli niiromnntic si'C|ui-l, thnn that of the inception nnd per-
fection of the nickel-copinT iiidiislry of Onliirio nnd N'ew Jersey. I'ldike other thrill-
ing accounts of chance tinds an<l fortunes won at the imint of tlu- pick, that of The
Canadian Copper Co. primarily, and of the Orford Copper Co. secondarily, has
more of scieiitilic purpose and the prolilcmatical in it. Tliat (lie denouement has lieeii
industrially felicitous is the more noteworthy in view of what was slated and implied
iiy .Alfred K. Harlow, M. A., U. Sc, when he wrote:

"The history of the <levclopmcnt of niininj< in the Sudhury district (of Ontario)
is, in the main, that of The Canadian Copper Co. It was the first conihination of
capital which seriously undertook ihe iiusiness of miniuK in this area, while, at the
same time having the distinction of heiug the only corporation which has continued
its operations without serious interruptions, frou. the commencement until the present
time."

That puts cause and effect concisely. The mines, metallurgical works and power
plants of The Canadian Copper Co. are situated innnediately to the west of Sudhury,
with headcpiartiTS at Copper ClifT. The existence of nickel had heen vaguely known
since 177(». (ieological reports of '4S-I!I also refer to nickel on the north shore of
Lake Superior. In the Sudhury district the first authentic discovery was recorded hy
.Mexaiuler Murray, who in his report to the (ieological Survey of Canada, IHtVi-oli,
mentions the strong deviation of the compass noted l)y Mr. Salter while running a
meridian line near what is now the Creighton mine. Mr. Murray sought out the
cause of this deviation and found an inunense mass of magnetic trap rock. He took
samples of the rock and ascertained that it contained magnetic iron pyrites, and small
(|uantities of nickel and copper.

In those days the few residents of the locality had other husiness in hand than
"geologizing," or ''rock-knocking," as it is described in some parts ; so '27 years elapsed
before the matter was deemed worthy of attention. Then the Canadian Pacific rail-
way, in 188:5, being under construction beyond Sudbury, was instrumental in again
bringing these mineral-bearing rocks into prominence. A stipendiary magistrate
named McXaughton had wandered and become lost in the vicinity of the railway
right-of-way. His friends sought and found him. One of them. Dr. Howie, observed
that thp knoll upon which the magistrate was seated was mineralized His curiosity
induced him to take samples which he submitted to Dr. Selwyn, director of the
Geological Survey of Canada, the result being that they were pronounced to be value-
less, there not being enough chalcoyprite, and the more plentiful pyrrhotite being
economically worthless.
1 Two years later this authority is said to have reversed himself, without detecting

4 UIKJANIZATION AM) IK^l II'MKNT OF

iiirkri, hiit rrport RhowiiiK i-ii|)|>rr, without uny rrfcrrncc to nirkri cnntrnt. An nimo-
cialr niiMcriiliiKisi .'ivrrrtd llif s|n'i-im«'ns Hiihniitlcil to him fi>ii<ii<(tj'<| of "niaKHctio
|)yritL'» ami roppfr pyritiit" mlimatcly rciati'il to a "«lark-j<rei'ii, linr Kraii"'' liioritc,
and n Kr .m^Ii urcrn ihloritic schitl." A few picccH wrrc partly "coatid with hydrati-d
peroxide of iron," and tlie analyHi* wn»: '"I'.'.W/, iron, \iM% copper, I8,(t»9^ sulphur;
insohihle mailer (KiniKne), !l<i.ii:i',i.

The siicnlist was in error. Xiikel wan not detennined. The pionecm were after
copper; the incident attaching to the Canadian i'acilic railway culling atui the stray
manisiralf started prosptitinn in !KW| Amon^ Ihc lirst pronpiTtors were Stohie,
MiCoinull, I'rood, McAllister .ind Nhtialf Ore was located by Frood and others
on lot (3, concession l(, in McKim township, aiul McC'onnell had more on lot |, con-
cession 4, Snider township. .Snlise(|uently those liecaine the F'rood and Clara Belle
properties. The Mc.Mlister mine was simultaneously located in lot I, concession ,'l of
Snider; it hecanie the Lady Macdonald in IHKil, in honor of a visit to the nickel-copper
fields then paid by VV. C. Vanllornc, president of the Canadian Pacific (now Sir Wil-
liam). Sir (ieorKe Stephens, Sir Charles Tupper and several Montreal ca(>ilalisls. At
that moment those men were amoiiK the most inlluential in Canada. They ha<l it in
their power to command the new ininiiiK fields. Their Montreal friends already were
parlicipaliiiK with The Canailiaii Copper Co and they .have remained as shareholders
to lienelit from what has been accomplished by that company. Whelher it was ihcir
powers of divination or their disincliiialion to lend themselves to inininK enterprises,
the trio of Sir KniKhts refrained from invesliiiK. Other Canadians could take the risk,
and did, f<ir there are numerous shareholders in the Dominion. The zeal of the
Canadian I'acilic inaKnates for lonnaKc for the railway and business for Montreal
(lid not carry them lo the reckless sta^e ; they were wise in their Reneration.

THE CANADIAN rOI'I'KR CO. OROANIZEn.

Canada's great railway was more happily placed than the Central Ontario railway,
of which S. J. Ritchie of Cleveland, ()., was president. Mr. Ritchie needed toimage,
and was prepared lo take his road after it. lie had enlisted the late Senator Henry
B. Payne, Judne Burke and Thomas Cornell of Ohio in the Hastings, Ontario, iron
fields.' In their sphere those men were as potential as the aforementioned Canadian
Sir Knights. They had to do with large affairs and corporate interests, and being
receptive toward anylhing lliaf looked big enough, Mr. Ritchie had in 18H-J convinced
them that the Hastings Ci>. iron ores were of enormous extent and value. They
accordingly acquired TO.Ono acres, organized the .\nglo-.-\merican Iron Co.. and built the
Central Ontario railway. They then learned that certain jirecautions arc prerequisites
in mining undertakings. A shi|)ment of the iron ore was sent to Cleveland, was duly
tried and found to be economically unlit — there was too much sulphur. The group of
capitalists was certainly up against a hard scientific pro|)osition. The Anglo-.Vmerican
Iron Co. and the Central Ontario railway seemed to be expensive memorials to
Ohioans. However, Mr. Ritchie was a man of many resources. When he heard of
the rich copper discoveries made on the line of the Canadian Pacific it occurred to
him he might get some traffic. That is why be went to Ottawa in IHKt and examined
the samples taken from the Canadian Pacific and "Soo" cuttings. They intluenced
him to proceed to Sudbury. There be concluded that W. B. McAllister of Pembroke
and J. II. Metcalf had the pick of the areas thus far prospected. Acting with the
authority of his Ohio colleagues, he purchased their holdings. On further investiga-

I 'i

TIIK CANADIAN <(HM'i;U ( (». 9

lini) hr olit.iinril ()|)tii)iiH and iiunhiisi'il various other propcrtic* Tlitsr lattt-r were
llu' MiCninull (C'<ipi>tr ('Ii(T), ilu- r'niml (now No. '.\) and ilu' CrciKliton N'rxt the
KvaiiH Krotiiiil wa* iik-liided. Thfii Tho Canadinii Copprr Co, wai conceived in \HXt\,
and rcnistcrrd in IMHil, willi a capital of $j,tMi(t,nitn, snliM-iinintly increased f<> $'.'.r»(»0,(>00.
Tlic Creaii liiil nickel properties were piircliasc<l hy the .\n|{U)-Americaii Iron Co.

MOKK IM-MCHASKM AND MININd HKdl'N.

Hctween llaslinKs iron fields and Siidlmrv mineral lands, the Ohio [jcople were
amply provided as to acreaxc Oltlivious of what ihcy were almut to encounter, they
began operations. I'nrther alonR in IH8«1 they purchased the Stohie property, in lot ft,
concession I, HUvard township. Stihseipiently the l'"rood section was extended hy the
acquisition of the soiuli half of lot 7. concessit . (i, McKim township, for |M0,0(»0.
That was the year in which the "Soo" hranch railway was laid from Sudbury to
Copper ClifT; it also v.-'-. a year of amiiitious programs and j{re;iter disappointments.
Combined companies capitalized at $7,-''iO(),()()0 had scmicthinn like !l",000 pri>l>lematical
acres, all paid for. Analyses showed there was liiKh Kr.tde copper in the McComiell,
or Copper ClifT, as it was <lesiKnated. NolhinR was known or surmised reR,<r.lin< the
nickel content. There w.is an ore which cmihl he sorted np to \^//r copper. Ilrrres-
hofT of the Nichols Co. on r.onn Island siKnil'ied his williiiKness to accept consiRH-
ments of such ores. Colonel K. M. Thompson of the (Irford Copper Co. at Cons able
Hook, N. J., was another tenderer. Copper ClitT was elated.

Minit!K lienan in the Ontario "wilderness." Some .'KMHI tons of ore were taken
out, sorted to Krade and shii)pcd to the Nichols Co. and to the Orford Co. The
Canadian Copper Co. was on the sunny side of the thoroughfare. Its officials con-
fidently antici(iateil the returns. When the returns arrived they were accompanied
by somelhiiiK more vigorous than invinoralinK- Ke^rcts were expressed and recrimi-
nations spread upon the minutes. Nichols bcKKcd to be excused from further ship-
ments. There was something; decidedly "(|ueer" about that ore which Nichols '-ould
not f.'ithom. Undoubtedly there was copper in it— i)leiity of it — the copper would not
be reasonable. Tliey, therefore, were prepared to surrender their rights in further
consignments cont'.'.nplatcd to Cf)lonel Thompson and his Orford Co., whose works
were very coiivn.iently located just across the bay from Long Island; it would be no
trouble for the Nichols people to transfer what they had to Constable Hook, if it was
all the same t(. Copper Cliflf. No doubt the Orford could do something with the stuflf.

At Orford, Colonel Thompson was no haiipier. He always had been keen for
research, but that Copper Cliff ore sorely vexed him. His works did not get copper,
try as they would. What they did get was a peculiar weird, grey-pinkish alloy, abso-
lutely unsalable. He was nonplussed with the mmameable mess. His chemists were
deputed to ascertain what was the matter. He was renewing the experiences of the
(ierman miners of a century previous with a similar ore, a copper ore that would not
produce copper, hence its appellation — "Kupfernickel," meaning "Old Nick's" copper.
The Orford Co. simply h;ul to make the best of it. Inability to solve the problem
meant bankruptcy. Colonel Thompson was against a situation of his own making.
.'\s far back as 1878 he had begun to invite what was happening.

Canada's first nk kei, venture.

It may here be explained that Colonel Thompson and Mr. Eustis, in or about 1878,
owned a mine near the village of Orford, in the province of Quebec. The mine had
nickel in it — the metal was then worth probably $5 a lb. They did not know much

tt OIKJANIZATION AND KQUIPMKNT OF

alHiiit iticki'l. The owiuts put up a small ri'vcr))erat()ry funiaci' and trifd tn siiu-lt the
lire, James MeArthur, a disciple of Sir Henry Hessemer, lieinn their fiinuu-e matiaKer.
Needless to say, they were in troiihle from the ontstart. The sUik was too stiff, the
metal would not separate — the enterprise was a t1at failure from the start. LookiuR
for something easier, the partners hou^ht the Capelton mine near liy, a low copper
ore high in sulphur. Then they put up the lirst Kachette furnace i.. Cana<la, 10 hy 3
ft., of brick, which accomplished the puri)osi'. It made uiiUte which was shipped to
Hunt and Douglas at I'hoeni.wille, I'enn.

OKi-dKll WOKKS KST.MM ISIlKli IN NKW IKKSKV.

l'"or a while all was merry, (."olonel Thompson wever believed in doing things
by halves. He chafed because some one else was making ingot copper out of his
matte. He wanted the |irofits frcim mine to market in his own account. There was
a duty on ingot copper entering the states, whereas matte went in free. Conse(|uently
it was decided to erect a refinery in the states, and as a site for this the siuiken
meadows at the end of Constable Hook in New Jersey, in the lower part of New
N'ork harbor, were selected. He purchased four acres of the swampy country and
l)repared to till it in. Henry M. Howe was appointed manager, and the combination
was hopefid. The place was unhealthy. The promoters of the enterprise had diffi-
culty in securing labor. Mr. McArthur and Mr. Howe stuck to it, however, and it is
recalled that they successfully negotiated with New York authorities for ashes, gar-
bage and refuse of any and all kinds as tilling. When they had finished, the furnaces
were erected and the Orford Copper & Sulphur Co. was ready for business, the com-
pany taking its name from the little Canadian village of Orford in Quebec, where
Colonel Thompson had first encountered and abandoned his nickel ore some years
before.

Alongside the Orford site at Constable Hook the Standard Oil Co. had been simi-
larly engaged in making land. When it had gotten far enough along it wanted sul-
phuric acid. Colonel Thompson concluded it would be mutually advantageous if he
shipped Capelton ore direct to Constable Hook, or Rayonne, closing down the Eustis
furnaces, and supplying the Standard Oil Co. with sulphuric acid from the sulphur in the
ore. Another project, advanced by a man named Chaddock, agreed to take the Eustis
ore, roast it near the Orford works, jiipe the acid to the Standard Oil plant and return
the roasted ore to the Orford Co. free of cost.

The Orford works were started with Mr. McArthur as furnaceman on one shift,
Sam Leek as furnaceman on the other, and with Mr. Howe as manager. Later they
imported Charles Rartlett, who had been running the furnaces at Eustis. Bartlett
was assigned to the reverberatory furnaces, where the company was making a blue
metal. Dr. Peters, who had been employed by Hunt and Douglas at Phoenixville
making ingot copper, was retained, and with this staff Colonel Thompson hoped to
have his venture equipped for any emergency. Unfortunately Dr. Peters resigned
and went to the Parrot Works at Butte, where they were experimenting with the Man-
hes process for converting copper. The Parrot Co. had Frenchmen from Lyons dem-
onstrating the process, on which President Farrcll held the patent rights in the L^nited
States. It was French practice never to cliarge more than 1100 lbs. of matte in the
converter, consequently their charges frequently chilled. Dr. Peters took issue
with this procedure and recommended that James Mc.Vrthur be employed as furnace
manager. This was done, and the Frenchmen departed. The new force got better

THE CANAIMAN COl'I'KH ("(). 7

results from the converter. At oiiee Anai-onda skeptics who had scoffed at the con-
verter, sought rights fur its use in their plant.

ORICIN OK lU'TTK KKHrCTlllN WORKS.

Things went alouR sniootlily for a year, so iniuh so tiiat Mr. McArthur joined
with some of his fellows in startiiiR a smelter of their own. Rutte had hegun as a
silver canij). Its old dunijjs were rich in copper. Between them the lu w conihination
mustered ahoiit ^l'.Vmmi, and with that they purchased 4(t acres, an<l init up a water
jacket furnace, in which they made excellent W/,- matte. As anticipated, some of
the dumps had 7% copper. The outi)ut of the smelter was satisfactr)ry. Settlements
were to the contrary and coke cost $l'7 a ton. Eventually it was necessary to go to
VV. A. Clark, from whom a loan was solicite 1. Mr. Clark let them have it and took a
lien on the |)roperty and plant, which soon went to the mortgagee. That was the
heginning of the Butte Reduction Works.

Meantime Colonel Thomi)Son met with reverses. Hardly had tlie Orford Co.
started to work than Mr. luistis concluded to take the Canadian mines as his share
of the iiartnership, leaving the Constable Hook plant to Colonel Thompson. I'inan-
cial difticulties arose. Opportunely a hVench syndicate, alleged to have $!)0,()0(I,0(K)
(or that many francs), contemplating the purchase of alnio.st all llie copper nnnes in
the states, as well as the smelters, made a deal with Colonel Thompson. He promptly
accepted their terms, which relic\ed him from his embarrassments, That was why
he went to Butte and imdertook to get western smelters ; send cojjper ores east to
him for treatment. He met Mr. Clark and the late Marcus Oaly, both of whom de-
clined to entertain that idea. Thereupon Colonel Thompson went prospecting. His
health could nf)t withstand the severity of the rough life, so he again sought Messrs.
Clark and Daly, with a view to having them ship concentrates to New York and let
him smelt them. Mr. Daly was obdurate.

ANOTHKR START AT ORKORM.

As Stated, Mr. Clark had the plant that was built by members of the Parrot staff.
The French syndicate, controlling the Orford plant, went wrong before its payments
were completed. The Orford Works reverted to Colonel Thompson and he again
sought Mr. Clark, who consented to an arrangement. Mr, Clark had ascertained that
Colonel Thompson knew his business. .A bargain was struck. Colonel Thompson had
mastered copper sniehing. Mr. Clark had satisfied himself t)n the point and agreed
to put up $(l(t,(MlO for one year, on condition that he controlled the smelter and was
allowed to send his own men there. Colonel Thompson at once resumed operations
at Orford, Mr. Clark shipping matte there to be relined. That v\ as in 188(1-7. Colonel
Thompson made enough in a year to wipe out his debt. He was again in quest of ore
and was told by John Blue that there was "a mountain of copper at Copper ClifT in
northern Ontario."

■ft

DISCOVERY OF THK ORKORO .MCKKI. PROCKSS.

We are back again to the starting point of Copper Cliff-Orford metallurgy. Col-
onel Thompson and Mr. Ritchie came together, and it would seem as though "Old
Nick" was the former's inevitable business partner. With furnaces and plant equipped,
Orford prepared for expansion. Mr. Ritchie's company was in the market with ores.
Nothing appeared more roseate than to take those ores and prosper. Colonel Thomp-

()R(iANIZATI()\ AND KgilPMlONT OF

soil was dated when shipments from Copper ('lifT arrived. Alas fur tlie frailty of
human expectation, Orford could not get copper out of this nice clean chalcopyrite.
The Orford chemists were peremptorily directed to "fjet husy." They did, and after a
while Rohert Medley reported the presence of Colonel Thompson's arch enemy — nickel.
Nickel had hested him once. 1 Ic determined to master it. SurveyinK the international
situation as to nickel, he learned that at that time the Vivians in Wales were the only
nickel redners in England. Beyond that his incpiiry could not penetrate. There was
nothiiiR in the patent records, and the text 1 ks were silent. The Vivians had pre-
served their secrets for a century. All the Colonel could find out was what any one
in the gallery could see. Cargoes duly arrived at Swansea. Copper-nickel ores were
discharged and taken to the Vivian plant. Nickel and copper came out of the works
and were shipped to metal huyers. It was hardly a satisfaction to ascertain that the
acid works sold a lot of what they called "Sallie Nixon" to the Vivians. However,
Colonel Thompson consulted a dealer in chemicals whom he requested to send him
some "Sallie Nixon." The dealer reiwrted that "Sallie Nixon" was crude sodium
sulphate that liore the ancient alchemistic name of Sal Enixum — washed out salt — it
heing the salt that is washed out of the retorts in making hydrochloric acid.

Several harrels of "Sallie Nixon" shortly reached New York and were delivered
at Constable Hook. The Orford Co. began to smelt matte in crucibles. It is not to
be inferred that the Vivian secret was thus surreptiously obtained. I'ar from it. The
Orford management found that if the matte and the sodium sulphate were melted
together, there was "nothing doing." Coke in the mixture was tried, and it was ob-
served that when the crucible cooled and was broken, two substances were in evidence,
clearly defined, so the top portion could be broken off. Analysis .showed that the
bottom was higher in nickel and lower in copper than the top. Increasing the amount
of "Sallie Nixon" did not help the separation. Finally Mr. Gibb suggested the re-
smelting of the bottom. I'lxin this being done it was noted that the second bottom
had less copper in it than the first. This procedure was rei)eated. After nine smelt-
ings they secured a bottom practically free from copper. Some of this was roasted
and found to consist mainly of iron oxide and nickel oxide.

MET.M.I.l'KGY OF NICKEL POI-VEfl,

When means for the removal of the iron were devised, the Orford process was
almost completed. Colonel Thompson and his staff were solving the metallurgy of
nickel. In the interim other things were going on. The Canadian Copper Co. had
taken Dr. Peters from the Parrot Works, and requested him to erect furnaces at
Copper Cliff, to reduce the ore to a matte, and save the great expense in freight. Dr.
Peters had l)rought Mr. McArthur along with him as furnace manager. .\ site for a
roast yard was chosen, and in the summer of 1888 the first roast heap was fired.
Meanwhile several others had taken in hand the nickel problem. Colonel Thompson's
people were perfecting their process and were making the separation, and Mr. Ritchie
and his colleagues of The Canadian Copper Co. were intent upon the more important
question of what they would do with the nickel when it was separated in quantities.
Curiously enough, Mr. Ritchie had had some experience with nickel beforehand — it is
a coincidence that he and Colonel Thompson could not escape from "Old Nick." This
phase, as effecting Mr. Ritchie, is given in Coleman's report to the Ontario Bureau
of Mines in 1005. The gist of it is that in 187() there was a yellow fever epidemic in
the southern states. It was recognized that frost killed the fever germs. Mr. Ritchie

THK ( AXADIAN COITKU CO.

was in Washington, where he met John (ianinee, an I-Jimhshnian, wlio had an idea
about building a ship on which a refrigerating machine would keep the i-mperature
below fret zing. This was to lu' moved around the gulf ports taking on fever patients
and freezing the germs out of them. The senate conunittec promised $'J.')ii,(l(Hl for
such a ship if Gamgee proved that he could maintain an even temperature therein;
and it [)ut a large shop and all machinery for experiment at his disjjosal at Washing-
ton, (iamgee started on annnonia machines, and soon found that cast iron would
not hold compressed ammonia gas. lie tried all kinds of alloys. I-'inally he and
Ritchie went over to the Smithsonian Institute and looked over the meteorites, which
are nickel-iron alloy. Camgee sent to Wharton of Camden and ol)laine<l some nickel.
lie commenced alloying nickel and iron and got a very tine alloy, which held the
gas. Reing erratic, however, fiamgce failed to agree with the senate committee about
the cost and maintenance of the shii>, and the whole scheme fell through.

THK FIRST .\KM()K l'l..\TK.

Recalling those experiences with (iamgee, ai'd the exceedingly tough alloy tiickel
had formed with iron, Mr. Ritchie wrote to Krupp and endeavored to interest him
in the matter. Long range negotiations being tedious and somewhat ineffectual, Mr.
Ritchie concluded to go to Europe and interview and interest steel makers in
nickel-steel. The Canadian govermnent co-operated to the extent of ai)pointing Sir
Charles Tuppcr, and the .Vmerican govermnent appointed Lieutenant H. 11. Bucking-
ham to investigate the sid)ject. Accordingly the trio visited all of the I'jiglish and
Continental steel plants, and created a decided interest in the matter. The outcome
was that James Riley of Glasgow began the study of nickel-steel, and in 1H8!) he read
a paper before the Iron and Steel Institute, which was the beginning of the nickel-steil
industry. That paper was presented to General Benjamin F. Tracy, secretary of the
navy in President Harrison's cabinet. He was so impressed with it that he ordered of
Creusot an armor plate of nickel-steel, and of Cainmel of Sheffield a plate of com-
pound steel, such as was then used by the British admiralty in their naval ccjiistruction.
Those two plates were tested at the Annapolis proving grounds, and the nickel plate
was so much the superior that congress immediately voted $1,000,000 for the purchase
of nickel. Thus the nickel-steel industry was given its status, and a start made toward
the broader conditions upon which the metal was dependent.

TROfBLF. AT COPPKR CI.IFF AND IN METAL MARKETS.

Progression was dolefully tedious. During the investigations further afield, as
outlined, Dr. Peters was wrestling with accumulating troubles at Copper Cliff. There
was a railway, it is true, and certain facilities, but building houses, clearing ground,
erecting shops, track laying and so on, practically 200 miles from a machine shop,
made for tribulations and objurations. Nickel ores could never be dealt with in
piecemeal. In the very nature of things they called for comprehensive treatment by
men of money and affairs. Finally a 100-ton Herreshoff furnace, and the necessary
plant to maintain it, was ilnished. On December 22, 1888, the first furnace was
started. Details of those pioneering days, descriptions of the frequent explosions at
the furnace and of the green workmen, bolting like scared rabbits at every unusual
sound, recitals of the struggles of the manager night and day to keep the process
going, would consume more space than is available. In retrospect they are all part
of the romance of metallurgy as it began at Copper Cliflf. At the time discourage-
ments were distressing if not altogether promotive of despondence.

ORCANIZATIOX AND EQl'II'MKNT OF

MOKK NKKKI. THAN THF. WORLD WANTKII.

The furnacf was a success. Dr. F'eters, who like other coiiipctent technical men,
was not infrequently wedded to his idols, was asked to extend his plans in order to
increase the capacity of the smelter to .'loo tons i>f ore a day. To this his reply was
that while no other plant in .\merica was snu'lting so much, and while such larRe
gures were very hewildering, yet he would do his best to oliline the manaKcment.
Consequently, next year another furnace was lilown in. That is how the realization
was speedily reached that The Canadian Copper Co. was shippin)^ more nickel in the
matte in 1?-H!» than the world consume<l. Colonel Thompson was getting along toward con-
tinuous separations, and the Copper Co. was wishing he would hurry. Markets were
narrow and i.xp'.ii(!ltures heavy. Mr. Ritchie was an optimist in his views on nickel-
steel, and was conducting a propaganda. The Orford people were gaining experience.
So were Messrs. Payne, Murke aiul Cornell in Cleveland, the original I'lnancial spon-
sors for so much of it all. They were pledging their private fortunes to secure over-
drafts and conserve the credit of an industry, whose creation had involved them in no
end of outlay. Never was there greater need of goiid business sense and unity of
purpose. Sales of matte were small and scattered. An initial sliipment of matte
went to the Vivians at Swansea. Tenant & Co. of London were taking a little,
Joseph Wharton of Philadelphia and his former partner. Mr. I'Meetman of Iserlohne,
and the French nickel producers were occasionally willing to accept consignments.
What matte was going to the Orford Works was piling up in the furnace yard. On
the other hand, by maintaining activity and proceeding with the production of the
matte. The Canadian Copper Co. had devdopcil an envious en\ ironnu-nt. .\t all
events numerous nickel ventures were inaugurated by a number of individuals and
companies unfamiliar with the tribulation of the most important factor in the locality.
If they could have had a look at the overdrafts — in some cases amounting to !?■_'")(>.-
000 — the game would have been less furious, disillusionizing instead of alluring, to
foolhardy novices. Even where experience shoidd have assured success, the ViviariS
failed. That firm hastened into the field, bought the Murray mine and prepared to
erect furnaces.

THE VIVI.W K.MI.l'RE.

All Canada was enthused over the advent of the N'ivians. They represented British
capital and perfected methods which had been in use for a century. Nickel was now
coming into its own. More areas were incidentally acquired by venturesome specula-
tors. Probably the promoters of The Canadian Copper Co. ruefully contemplated
such competition following on their endeavors to establish an adequate market for
their matte. No doubt they aTiticipated ruinous rivalries. It might have been so
were it not that the Vivians sent ov^r antiquated machinery from an abandoned mine
in Norway. Copper Cliff ceased to grieve. When the Vivian furnace was demon-
strated to be inefficient and capable of smeltuig less than a third of the furnaces
erected under the direction of Dr. Peters there were juhiliations at Copper Cliff.
Dr. Barlow, in his capacity as a distinguished member of the survey, has fittingly
described the Vivian episode. He connnents bitterly on the lack of technical knowl-
edge shown in this venture. Local tradition preserves the story of the action of the
British directors solemnly and satisfiedly ordering diamond drill holes put down in
the granite and overruling the advice of their local manager. By this time cordial
relations prevailed between the Vivian staff and The Canadian Copper Co. There

TIIK CANADIAN COPPKR CO.

was IK) si-iTi'cy. Mutual frccdoiu uf acci-ss was graiitcd. How \hv X'ivians failfd is
not a inystt'ry. Loudon directors know more than the men on the spot. It cost the
Vivians $:{7ri,(io(i to (leinoiistrate their stuiiidity. Nor were they alone. Of the other
linns ciiterinK upon mining operations and ex|)erimeiilation with processes, little need
he written at this date. Among tho.sc were the Dominion Mineral Co., whose opera-
tions contimied from 18M!> to I8!t|; ihe Drnry Nickel Co.. the .Mgoma Nickel Co., the
Funniens Metal Co., the lloepfner KefiniuK Co., the (ireat i^ikes Copier Co., the Lake
Superior Power Co. .MI of these are mer"ly nulestones marking the progress of
The Canadian Copper Co. Perhaps they migi^t he more correctly delined as tomh-
stones in a large graveyard devoted to the r'.Iicts or derelicts of the nickel fields
The comiiaiiies enumerated could mine aii'I make matte, hut they had no relining
proccs.s, and nickel matte is not a salahle rti:le. Of those remaining and uiii'ro-
ductive, the Dominion C"oi)per Co. is the mi» imixirtant.

A (AN.\ni.\N KKKINKKV AIMKn AT,

haihue was meanwhile heing excluded from Canadian Copper Co. anticipations.
Colonel Thompson was out of the woods and taking more matte. Cradually the
nickel-steel hunincss was expanding, and bank overdrafts reduced. Realizing that
political and economic consider;itions invited the provision of a Canadian relinery.
The Canadian Copiier Co. sought a process of its own rather than be tied up to one
relinery in New Jersey. In this endeavor there was the additional incentive, that it
wf)uld be injudicious to patroni/.e the Orlord exclusively, and leave it within the
power of Colonel Thompson to operate nickel mines on liis own account. To meet
this latter contingency and to satisfy Cana<Iian sentiment, if possible, The Canadian
Copper Co, decided it must have its own process of retining, and further, that this
refming must be done in Canada. .Mready, in 1«8!), Dr. Peters had proposed a re-
linery at Caiie Breton, where cheap coal and ocean freights offered more advantages
than conld be .secured in coalless Ontario. His plant was never realized. His furnace
troubles at Copper Cliff were all sufficieni for him. In WH) The Canadian Copper Co.
therefore retained Jules (iarnier, the di.scoverer of nickel in New Caledonia, and
gave him carte blanche to solve the retining problem. He went to Copper Cliff,
erected a Hessemer plant and proceeded in 1H!)1 to reline the furnace matte and bring
it up to 8(i7f copper-nickel. That matte was shipped to Cleveland, where Mr. Ciarnier
had erected a relinery with cupcdas, gas producers and hot blast stoves, Siemens
furnaces and all the paraphernalia of the modern alchemist. Mr. Garnier's experi-
ments were unavailing. The experience with him cost The Canadian Copper Co
$1.50,000.

Another attempt was made by Hoepfner, who spent a year and some $.')0,(iOO in
illustrating how not to do it. Ohio was not unwilling to have Hoepfner try his hand
elsewhere. He transferred his services to the lloepfner Refining Co. of Hamilton,
Ontario, with the subsequent failure of which Dr. Harlow deals.

invk.sti<;atin(; thk mono process.

Once more, in 180."), The Canadian Copper Co. sought a process. It sent its
metallurgist to England to study the Mond process. This invention of Dr. Carl
Langer is probably the most beautifully intricate and metallurgically interesting in
the whole realm of modern research. For a year the process was watched and then
regretfully declined as not being suitable to the rigors of the Canadian climate. Dr.

ORGANIZATION AND E(ii;iFMENT OF

Mond evidently was of the same opinion, for when, in l!t(>0, he ac(|niri'(l tin- \'iitnria
iniiii' iiiid iTvctt'd liis snu'ltiTs thrrc, hi' loi-aled his ri'liniT)' in W'aK-s, whiTo olicap coal
and aciiis connterbahmced the long matte haul. After experinientiiiK with the Mond
process The Caiia<iian Copper Co. worked out a metliod of its own and put up a small
electrolytic elinery at Cleveland, with which for a year or two it supplied a superior
grade of metal to "(ierman silver" refiners. While that process was successfid, its
costs in comparison with those at Orford inaJe it prohibitive. Kepeated returns to
the attack duriiiK those years had demonstrated that nickel could he relined. Processes
galore were elTiclive, hut "Sallie Ni.xon's" offspring ai (Irford, in point of ecnnom>,
held an advantage a haiid-toinou'.h nickel industry could not with impunity forego.
"Nothing in science is impossible," the management stoutly declared. "Certainly
nickel can be refmed in Canada, but it camiot be done here at a cost which will
enable the Canadian nickel to com|)are with that produced abroad.''

All of this time tbe plant at Copi)er Cliff had been growing little by little, here a
shed, there a shanty, until In works were a labyrinth of glorified lean-to's, worse
than a maze to a stranger. T!'e V.;\f' smelter had grown to si.\ furnac?s in 1800. In
that year the West s nelte •, \' \'h sc ii or i.iore tinpot furnaces, startei'.. The Orford
Co. in 1000 put u]) at Copper C • refinery known as the Ontario Smelting Works,
which took the furnf • matte pr luced at Copper ClifT, containing 3.")% of metal and
refined it up to i •'>'/( , '(ling this refined matte to the Orford works at Constable
Hook for further treatment. 1 he. .• was no connection at the time between The Cana-
dian Copper Co. and the Orford Copper Co. One had the mines and the other had
the process.

INTERN.\TIONAI. NUKKl. CO. ORCANIZKD.

Such was the status of the companies when the International Nickel Co. was
organized. When it became manifest that the Orford Copper Co. and The Canadian
Copper Co. were indispensable to each other, it was decided to organize a holding
company. In December, 1001, the contract for the purchase of The Canadian Copper
Co., the Anglo-American Iron Co. and the Orford Copper Co. was entered into by
Colonel R. M. Thompson, Captain DeLamar, E. C. Converse and Charles M. Schwab.
On April 1, 1002, they formed the International Nickel Co., after having gathered np
the stocks of the constituent companies and deposited them with the New York
Security & Trust Co. as the basis for a bond issue. The share capital was $'24,00O.O(i(l
with authority for $12,000,000 in bonds. Included in this larger organization with its
influential directorate, beside the subsidiary companies named, were the .'\merican
Nickel Co., the Whittaker Wright Nickel Corporation of New London and the Societe
Miniere Caledonicnne. None of these companies were what might be called com-
petitors. The Anglo-.Anierican Co., The Canadian Copper Co., the Nickel Corpora-
tion and the Societe Miniere had mines, The Canadian Copper Co. had furnaces and
could make matte. The Orford Co. had furnaces and could separate nickel from
copper. The American Nickel Co. had a wet process and was especially interested
in making nickel salts, copper sulphate, cobalt oxide and other by-products. All of
these companies were nnitually concerned about the nickel market. Their combined
shares amounted to $10,000,000. The promoters of the International Nickel Co. de-
cided to issue $10,300,000 in bonds and $18,000,000 in preferred and common stock.
The interest on the paramount issue has been met with regularity. It was not until
September of last year that the cominon stock received a dividend, notwithstanding

THK ('ANADIAN' ("ol'PKH CO.

the market valuiition placed upon the shares was over $lO(». For that matter, the
rt'tiirii tipon the securities nf tlu- International Co. tluis far has been sul)or<linate(l to
the larger policy of ImildiiiK and e(|nip|)inK their plants. It was so with The Canadian
Copper Co., orRani/.ed in IWKfi, and not having ma<lc a distrihution until IH'M. That
8-year-old dividend was H'/r, at the rate of 1% i^>r each of those disconcertinR years.
In IH!».'i and IK!MI Canadian Copi)er shares paid 7 and K'f respectively, making 2 .1/")%
spread over the !<• years, hrom 1HII7 to l!ln-_» the yearly dividend was 12%; so tliat,
if extended over all the years the capital return to Canadian Copper shareholders
to the time of amalKamation, was not si)ecially remunerati\t — ahout 79f per annum.
Gradually the International Ixnids are heinn retired. The preferred issue has been
receiving its (>% regularly for 5 years.

CIIArri'.R II.

GROWTH OK TIIK NICKKI. IlfSINKSS.

When Secretary William C. Whitney succeeded (ieneral Tracy as secretary of
the navy, and the Venezuelan or some other episode was endangering international
relations, Henry B. Payne, who was Mr. Whitney's father-in-law, took up the cudgels
for nickel. The personal factor saved a situation that was embarrassing at the
moment. There was more nickel on hand than was pleasant. The surplus disappeared
— went iiUo nickel-steel armor plate, thanks to Mr. Payne. In 188f) the toimage mined
in the Sudbury district was ll,ll!M), of which 10,14(1 was treated. In \H'.)\ the toiuiage
mined was 83,.'t(i0, of which '■iJM was treated for lti.:!:<() tons of matte "sold and
shipped." the nickel and copper contents of that being respectively I'ulK and 'JOtU tons.
Canada was then within striking distance of the T'ew Caledonia nickel output — "J 104
tons. The panic of I8!i;i reversed this order of things. In that year the nickel in
the matte dropped oflf to l(i.'»S tons and the copper to 14.31 tons. Two fat years and
two lean followed. After that the Spanish-American war lifted the nickel output to
2800 tons. Since then the growth has been gradual, notwithstanding temporary de-
pressions. From 3.')40 tons in 1900, the advance has been steady until in 190!), the
Ontario output totaled 13,142 tons, as given in the table of exports prepared by
Statistician McLeish at Ottawa. Of this 1022, or lo'/c, went to Great Britain. The
"spot" valuation of all the 1000 nickel-copper shipped was $3,013,012. The Canadian
Copper Co.'s share of that was $2,080,4()7, or 7fi%. It took 451,802 tons mined and
4(i2,3.3() tons smelted to produce 2.'),84o tons of nickel-copper matte. The Canadian
Copper Co. mined 3-18,()00 tons, which yielded 21,10.') tons of matte, 81% of the Cana-
dian output. In its fiscal year just ended The Canadian Copper Co. made a still bet-
ter presentation, approximately 24,000 tons of matte. Of that, 13.000,000 lbs. of nickel
were sold by the Orford Co., the relining and selling partner of The Canadian Cop-
per Co., at a profit of $1,027,000, so it has taken 24 years of wandering in what was
regarded as a "wilderness"' to force or coax nickel into the affections of consumers.
Those who have followed this recital, which is introductory to the mining and metal-
lurgical features, will appreciate that the splendid growth of Canadian nickel was
a matter of brains and capital, reinforced by geographical vantage and ore reserves
now conservatively figured at 30,000,000 tons, and of which more will be written later
in this review. The world's supply is assured to Canada for some time, irrespective of
other fields of greater or less importance.

OHOANIZATIOX AN'D K(irri'MKXT nF

MINER AND ONE RESERVES.

The Cniiadinn Copper Co. remains the predtuniiiant faitor in tin- prn<imti(>n of
nickel. Last year it aceonntcd for 81'/{ of the Canadian l)essenier niikel-inppir matte.
M nothinK occurs to npsct the ecinihliriinn of iron and steel trades llie present rate of
oiitpnttinK may he accepted as a fair measure of wliat ttie nickel intUistry will he
capahle of as occasions require.

ThrouKhont the career of tlu' company, more particularly in those years since the
formation of the liilern.ilional Nickel Co., there has heen constructive purpose, scien-
tific persistence, studied conservatism and the reipiisite, ready capital. Gradually the
intelliKcnt application of money, latterly the recoKuition of nickel steel as an indis-
pensaMe, wherever ureat tensile slreuKth is re(|uired. have estahlishd what was a nehu-
lous opportunity as one of the world's uiiiipie industries.

With the organization of the International Nickel Co. as the holding company, there
was co-or<liiiation of the coi-iiorate tniits, an^ressive endeavor to occupy a larger field.
While capital outlay amounting into the millions demanded nerve, there has heen a
campaiKii of education in the use of nickel steel and Monel metal, combined with pre-
cautionary writings otT for depreciat'on anil exhaustion of ore reserves, which, coiiici-
dentally, have persistently heen on the increase. Moreover, the profit and loss surplus
and sinking fund for the redemption of the bonds have been suhstaiUially replenished,
until the former is approaching the $;Ummi.(H)(> mark, having been $'_V)nO,00(» at the end
ot the fiscal year l!Mi8-!t, Mesides, it is claimed that "earnings to the extent of ap-
proximately $7") per share" have been put back into properties and plants.

After deducting expenses and bond interest the International Nickel net has
totaled almost $!•,(» 10,000. 'I'he spending power per annum of The Canadian Copper
Co. amounts to about $'2,000,000, and that there is more confidence prevailing, the pay-
ment of dividends on the International Nickel common .stock attests.

SLI'KKM.XCV .\NI) ITS KEWAROS.

"Exhaustion of reserves adjustments" no longer seem t<i be an essential, apart
from the business principle involved. Depreciation reserves have been extremely pru-
dent. The surplus each year after providing for all fixed charges and bond sinking
fund has varied from $.'>70,!Mit; in l!l()8-!l to $l,;y l,2.");i in 1000-7. Heavier capital ex-
penditure being unlikely, except for reverberatory furnace plant and b.isic converters,
and that special modification of metallurgical practice being an economy in that green
ore will he treated instead of being subjected to expensive and prolonged heap roast-
ing, necessity for radical safeguards no longer exists. Common shareholders who
almost despaired of reward for their patience are very apt to be agreeably surprised.

The success of The Canadian Copper Co. is remarkable in view of the fact that
this company has only about (»% of the 400,000 acres of nickel-bearing lands in the
Sudbury district.

Canadian ore bodies containing nickel-copper are at once the basis of credit, and
the sources of discredit to those who thought — and who still think — that all they had
to do was to find the characteristic rocks in quantities. There was a time when lands
now valuable, because of Canadian Copper Co, operations, were assessed at less than
it costs for a meal on a dining car. A wag has suggested that the "unearned incre-
ment" beneficially conferred by the company upon reactionary critics, should revert to
those who supplied the momentum and obliterated the memories of their initial efforts.
UnfortunPicly for all parties in interest, when there was lack of concert between The

THK CANADIAN COIMM'.U CO.

1.1

Canadian Cupper Co. and the residents of the district, the company hai not always
felt at lilierty to conl'ule its itic^esscs to the pulilic. Only cpiite recently has sufficient
hiiiilio.iiie olitained to make possible an exposition of what the corporation has
adiicved, of what it experienced, of what disappointments and risks were met with
and assumed, when the group of Ohio capitalists jauntily launched themselves upon a
veritahle Styx a quarter of a century aRo.

I'l.KNTV (IK NIC KKI. AKOINU Sl'IIIU'RV.

To have their purpose misinterpreted or misunderstood, when they were emerxing
from a ma/e of triumiih and tro'thle, was taken to he cause all-surticient why analytical
data atTectiuK nickel production and distrihution should he sparingly sup|)lied. More-
over, metal markets were narrow, and still re(iuire heroic stinmtants.

Hetween the Sultana mine at the southwest end of the nickel range, and the
Whistle mine at the northeast, an inunense amount of nickel-hearing laud awa.ts
development. The formation may he ilescrilied as an oval rin^t of nickel-hearing
eruptive. This oval is IM miles in width hy Xt miles in length. Around the circum-
ference is approximately 110 miles. As the same rock occurs all around this circum-
ference, and as diamond drilling has shown the presence of ore bodies widely scat-
tered throughout this rock, it follows that the present (levelo|)ment is iiilinitesimal in
comparison with the possibilities of the future. All the authorities are agreed that
the norites have more metallics than capital is willing to experiment with; so The
Canadian Copper Co., as one of the predecessors of the International Nickel Corpora-
tion, chose to contule in itself alone concerning its ore reserves until its domestic
affairs were thoroughly safeguarded. A matter of ,'(,'(,000,000 more tons of ore in
reserve, ;is estimated from hore-hole results, and expansion in the uses of nickel and
Monel metal, have contributed elements of certainty, and eliminated the factor of
difiidencc.

NKVV I'OI.ICV OK KR.\NKNKSS.

No longer can it be alleged that there is inordinate sccretiveness about Canadian
Copper Co. conduct. Doubtless there were periods when those who aimed at the
mastery of the nickel product and markets did not always concede to their rivals the
information desired. The cardin.'d thought publicly reaffirmed by Mr. Schwab that
"commerce is war" was displayed in vigorous maimer. Decisive influences in the
steel business brooked no interference where so much had been risked on behalf of
nickel as an adjunct to steel mai<ing. Again and again attempts to enlist other capi-
talists in nickel-copper areas have failed. Consideration of the issues, knowledge of
the economic facts and the potency of the men behind the nickel movement, coupled
with the object lessons afforded by those ill-conceived ventures in the Sudbury dis-
trict, have induced fmanciers to hesitate about undertaking large expenditures where
there was little chance of ousting the fixed quantities fortified with processes and the
possession of restricted markets.

WHAT OTHER COMPANIES HOI-D.

There is infinitely more nickel in Canada than the established companies will
recover, since it is agreed that the mineral exists in payable and problematical quan-
tities in an area 40 miles by 25 miles.

ORGANIZATION AND KCini'MFA'T OK

«ii)itiK around the oval in wliiih the iiuki-l ore it fiiunil, there ii at the extreme
soutinvi'st coriHT liu' Snliiuia mini-; tluii in ordrr follows thi- Cliiiano, and lu-xt to
this the Victoria, wluri- the Mond Nickfi In. lias taken out most of its ore. South
of the Victoria are the WorthinKton, Totteii, Mileheuer and utherit, on an olTshont
from the main raiiKe. (ioiuK east from Victoria is the Crean Hill, and south of this
a small deposit of liiKJi Krade ore known as tlie Vermilion, 'jhese are the most
westerly holdings of jlu' ('ana<lian ('(ipper Co. !''ast of the t'rean Hill is the (ier-
trude, owned hy the l-iike Superior Power Co., and then follows the CreiKhton mine,
The Canadian Copper Co.'s larKest |>rodiicer. I'assiiif{ further east is the North Star
mine, owned liy the .\lond Co., and then the I'.lsie mine, and the famous Murray,
where the X'ivians made their spectacular f.iilure South of the Murray lie the old
pits of Nos. I, ."» and (I mines, then No. 'J, the Copper ClitT, No. 1 and the l-'vans, all
owned liy The Canadian Copper ( o. .None of tlu>e except .No. 'J are proiluciuK mines.
Kast of the .Murray are the t amcron, Mount .Nickel, Hle/ard and the Sheppard, all
owneil by defunct corporations. .South of these on ;ni otTshoot of the main raiiKe lie
the Slnliie :ind the No. It, owned li.\ The Canadian Copi>er Co. Mast of the Sheppat.!
is the (iarson mine, owned liy the Mond .Nickel Co. l''rom that point east, a fewr
scattered pits represent all the development yet done. The rauRc from there swings
north past Wahnapitae lake, some l.'i miles, to the Whistle property, owned liy the
Dominion Copper Co. This is the extreme northeast corner of the nickel ran^e. The
formation can lie followed west over an entirely undeveloped area, on all of which the
nickel-heariuK eruptive mck is seen. The only development there has lieeii done at the
HIk l.e\ack and the Stratlicun.-i properties, which are directly opposite to the CreiKh-
ton mine, itnd |M miles roitluvest of it. The nickel eruptive continues unlirokenly
west ;ind curves south, joiniiiK the main or southern raiine at the .Sultana mine, where
we lienjin the circuit.

On the North Nickel ran^e a urouii of Canadian capitalists of prominence and
wealth have several thousand acres, which they have jirospected to some extent, and
which, it is said, will he broUKht to the producing sta^e one of these days. The trou-
lile seems to be that the nickel content is not as iirolitalily consistent all over the dis-
trict as it is in some of the selected properties of the noiiiK concerns. Certainly there
is scope for exploration, such as the Dominion Copper Co. may undertake, and at any
rate there is no monopoly of country, either in Caiia<la or in New Caledonia, where
the Singer .Sewing Machine people have begun to mine for themselves. On the other
hand the International Nickel organization has New Caledonia areas, which will en-
able it to meet competition from any and all directions.

SMALL PROFITS ON .\ LAK(;K TIKNOVKR.

Briefly, the International Nickel Co. has attained to pre-eminence, in that it com-
manded the support of most influential men and correlatively deterred others from
risking their funds. In l!»0(t it sold l:t,(lUO,000 lbs. of nickel at a profit of $1,027,000
— about 7V6 cts, per lb. — a significant fact, and one which makes it manifest why
there has been more faith than dividends in the production of the metal. On the
Moncl metal sold to the Pennsylvania and Chicago & Northwestern railways for the
roofs of their mammoth depots, there was a loss instead of a profit, because the
demonstration of the material was essential. Likewise it is true history that nickel
was a "slow seller" for more years than the management care to recall before nickel
steel was introduced into armor plates, deck plates, bridge work and heavy steel
construction.

THK CANADIAN COIM'KK «<)

AlthiiiiKh the Sinlliury diitlriit wan a ni<><lcrii (inlKoiha- innri- ho than many sul-
phide canipH thriiiiKlioiit thr iniiiiiiK world, iicforc iiiclailnrKV i°atnc to the rcnciu* —
thtTc is nil doidit that Tlic Caiiailian tupprr L'n. luT'afttT will havo the- solace con-
taiiifd in the Koran: ' Then as to hitn whose lialanics are heavy his shall lie a life
that shall please him well. And as to him whnsc l)alanceR are liKht, hii ttwelliiiK place
shall lie the pit."

THK FtKST Nl( KKI.-STKKI, Mll.l..

ft used to he said that if Whittaker Wright had stuck to his New Caledonia
nickel country, and kejit away from the .Xu^traliaii Deep leads, it would not have led
to his committinK suiciilo. The point is deliatalile. The Canadian nickel tithls were
ha|i|iily orKani/ed in Imt one resjiect ; wealthy men had metallnrKical anil m:irket prob-
lems in hand, and they linally foresaw more than the mere speculator in mines liothers
about. Carnegie's "youiiK men" contributed a status to the metal as refined under
OrfortI Co. auspices; Turner and his stalT have produced the raw and partly-retined
material. The I'nited States navy department authorities were rpiick to discern the
superiority of nickel steel. They discussed the matter with Mr. CarncKie, and with
the understandiiiK that there would be a rcKular demand for nickel-steel, a special
mill was erected at llnniestead for its production.

It has been cotneniled that nickel can be rclined and workeil into steel in Canada,
and that there may be a market here now that a Canadian navy is contemplated.
To this the facetious rejoinder is made that the Canadian navy minht re(|nire oO tons
of nickel for nickel-steel. The CariiKeie Nickd-Sleel plant is estimated to have cost
$.')(i(),(MMi. It has a capacity of .'(t.tMH) tons a month. Without the arrauKement with
WashiiiKton it miKht not have been built until later. Without it nickel-steel con-
struction would not be undertaken on a larpe scale. K. I'. Wood, who speaks c.v-
callicdra on the subject of the metallurgy of steel, says there is no advantage in
building a small bridge of nickel-steel, for there nnist be a certain amount of steel
for stiffness, and ordinary steel is good enough. lUit when a structure such as the
Quebec bridge is planned, there will probably be plates 8 by !M) ft, long, bars prob-
ably of lo to 20 by 2 Ins., up to 70 or 80 ft. The mills to roll these will have to be
very heavy and necessarily expensive, and they will cost millions. Citing as a further
example the eye bars of the Mlackwell bridge. New York, Mr. Wood explains that;
"They were 18 by >, made of nickel-steel. They were rolled on the 12-in. L'niversal
mill at the Homestead Steel Works, but the tonnage of bars rolled for the whole
bridge was from 'M»M\ to 40(iO tons." Conse(|nently the erection of nickel-steel works
in Canada would be premature. If we consider the $.■">,.■)( Kl.or i spent at Copper ClifT
and vicinity, the cost of mining and metallurgy, the hiatr..i between the purchase of
the properties and the declaration of H'/c in 181 4 on Canadian Copper Co. stock, the
return from nickel investments was tardily contingent on the acceptance of the metal
by steel masters. In I8!ir>-(;-7 the dividends were 7, 8 and 12%. From 18!»7 to 1902
the dividends were 12%. To do that and to make up for previous unprofitable years,
ni'-kel had to be sold at a price prohibiting its general utility. Even for special steels
nickel has been a costly item, considering that ■W*% of nickel at '.Vt cts. per lb., added
to the contents of the crucible, has been the practice. Should Monel metal meet
with the popular demand, markets will be simplified. That accomplished the Copper
Co. will be prepared for greater things, instead of alternating conditions governing
its mining and metallurgy.

OH<l,\NI)C\rH)N AND KC^III'MKNT OK

■J

Roc

Hill Mine

•— —

TMK rxN'MH \\ nH'i'KU ro.

3
C

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E

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ie

•M

OROANIZATION AND EtiriPMKNT OK

THIRTY MII.I.MIN TONS AMI MOKK ORE RESERVKS.

The Caii.'idian Coppi-r Co. has provod supplies of ore aiuountinn to at least 'M\-
OOO.OOO tons. This much the iiiaiiaKcnieiit acknowledges, althouKli rou«h calculations
indicate that those tiniires are ultra conservative. .\t any rate when tlie average
tonnaKe mined is maintained at .'lOit.iMMi per annuni, there will lie reserves suHicient
fur tio years, irrespective of what unexploited areas may show up. In this regard
the company is removeil from the prohlematical. It is not averse to the extension
of its holdings, liut it has not found any preferalile to what it owns. Ciradually
the variety and niagnitude of the ore bodies are being demonstrated and the policy
is one of expansion within its organixation.

WIIKN .\NII iniW MININC, llKd.VN.

Mining began at the McMlister, locally known as the Lady MacDonald, and
now No. 4. Next some prospecting was done on the ICvans. Later, when the Coii-
per Co. had taken over these an<l others, operations in 1887 were concentrated at
the Copper ClitT, that being regartled as the best. .\s already stated the first ship-
ments were made from the Copper Cliff, where the ore was handpicked for its copper
contents, (iradually the field of activity w-as broadened, and the complexity of the
whole proposition became more manifest. The company's headquarters were at
Sudbury, conunnnication was attended by vexations; a diarist on the spot has it that
there was no mail delivery for a week, and that it would be a blessing "if some one
would hitch up a bull-team and bring us our letters." .\ boy was fished out of the
mud on the highway where he tloundered to his death. Never was there a mining
venture in sorer business straits. Yet the record shows the obstinacy with which
the management pursued the programme.

More extensive mining began in 1887 at the Stobie, and in 1888 at the ICvans.
Then ten years were occupied in exploration, special efforts being directed toward
the metallurgy of the ores and the exploiting of markets. Drilling was resorted to
at Nos. 1 and 2 mines. This led to their being mined in 180!). The Trood (No. 3)
started in 1!KK», No. 4 in 18i)!t, Nos. ,1 and ti in 18!)!t. Most important of all events
was the discovery of the Creighton, "undoubtedly the largest mine in the district of
which we at present have any knowledge, and which from the very beginning of
operations has produced very large quantities of the almost pure sulphides, with
little or no rocky admixture."

So wrote Dr. Barlow in l!tO',". "It is essentially valuable as carrying a high
percentage of nickel, with a very much smaller proportion of copper." Another
pleasing development is the Crcan Hill mine. The Canadian Copper Co. has produced
up to the end of 1!)0!) some 3,.j00,000 tons from all its properties. Had The Canadian
Copper Co. remained a separate organization, the value of that tonnage as mined
might hypothetically be given as about $20,0110,000, that is if it had been possible to
dispose of it f. o. b. Copper Cliflf. The 1909 value of the nickel contaitied in the
matte now being produced is averaged by Mr. McLiesh, Chief of the Ottawa Division
of Mineral Resources and Statistics, at 10.7 cts. per lb. The same authority puts the
copper contents of all smelter products at 12.982 cts. per lb. Copper or nickel alone
is worth more than each is in the mixture, on account of the expense of separation.
In reality the export value of all the nickel-copper matte in 1909 works out at about
9 cts. per lb. Were the copper contents of the nickel-copper matte enumerated as a
distinct item, there would be no question as to the exact export value of the respective

1
I

THE CANADIAN COPPKH CO. Jl

iiH'tals ill tlu' matte. .\ iKiri/milal \aliiati(iii of :f."i in $ii por tmi miiu-d, as a coiuijro-
misc, iiiiRlit lint be so wide of the mark. ,\ lut profit of $l..")(l to $"J.0(» per ton mined
would tlu'ii lie a conservative, if imaiitlinri/ed, estimate of the return. Tliat would
mean a yearly jirofit of $.V_'-.',!Hmi, or $ti!l7,J(iii, as apiilied to i!lii!i mining operations.
The l.'U'OO.Otld il)s. of the iiiekel cHsposed of in I'M)!;, it is claimed, hrought a prot'ii of
7*/i ets. jier pound spread over niiiiin).t, snieitiiiK and relininji; charges.

IKKICMTON MI.NK I'rtOmiTION I'KOSI'KCTS.

An nnnsnal feature aliout the Creightoii mine is that it came near being one of
the first to be discovered, instead of being the last and best. Murray in IHoti noted
the outcrops of sulphide-bearing rocks, which really are an extension of the Creighton
mine. I'he (ieological Survey gave the cue. but Dr. Harlow attributed the delay of
a quarter of a century in the discovery to "the inaccessible nature of the country."
Not only is the Creighton "good to look upon" but in four years it has contributed
over W/c of the tonnage treated, and there are ."i.iHHi.doo tons of ore in process of
development without including certain extensions. Laterally 700 ft., and for a depth
of l!Mi ft., there are open-cast workings, all of uniform grade, only about I'/r of the
rock being discarded. The ore contains about \%' i coiiper and 4'';'7c> of nickel. The
highest monthly output from this mine was .V),00(> tons, and that for March was
47,000.

Of the total tonnage hoisted throughout the operating career of the property,
the average for the combined metals has been i>M'/<. A series of bore holes leaves
little to be desired as to the life of the huge lens in which the luanageiueiit is work-
ing. Granting that the ore section has been bottomed at an average of about 500 ft.,
the width of the lens at the 4th level is about 'J.'iO ft., as against 400 at surface. Ore
has been proved for 1500 ft. on the strike of the deposit, and it is inferred that
drilling will indicate more further on. The ore is so massive it (piickly makes tonna.ge.
If it has a fault, it is in its basic character which exacts the addition of siliceous
material when going to the furnaces.

THK CRE.VN HII.l, I'ROl'KRTV.

For the latter purpose the siliceous Crean Hill ore is admirably adapted. As
explained, Crean Hill is near the Victoria mines of the Mond people. It is the
latest of The Canadian Copper Co.'s large producers, having yielded L'OO.l'.VJ tons to
the end of 100!). This mine has extensive reserves variously estimated from the
workings and 27 bore holes throughout the property. Since the begimiing the Crean
Hill has averaged i't.'^'i'/'r of conibine<l metals, the copper lieiiig in excess, 'fhe disparity
between the metallic contents has been less pronounced in the lower levels.

Ore has been located to a depth of about 1000 ft. ; so with ti% of metals the
Crean Hill can supplement the Creighton for a good many years. To the end of
the year the mine was not drawn on to any appreciable extent. It lias high-grade
copper in places, and some very fine pentlandite. Northwest from the Crean Hill
there is an outcrop from which enough ore for a test w.-'s taken, and which satisfied
the managciuent that they have not ascertained all they are going to about this
vicinity. The Crean Hill is being developed along the same lines as the Creighton,
and it is the intention to have enough ore broken in the stopes to meet any and all
emergencies. General Superintendent Lawson has solved the difficulties accompany-
ing the mining of such large stopes as those of the Crean Hill and the Creighton,

OHdAN'IZATION AXl) K(il'IPMK\T ()

THK CANADIAN COPl'KR CO.

2:i

ORGANIZATION AND EQl IPMKNT OF

and it was through the courtesy of President Turner that the writer was favored
with a permit to go undergroutKl, so as to obtain a more intelligent, comprehensive
view of the exphiration and development done.

HOW THE I.ARliE STOPES ARE MINED.

To Start with, about five years ago, it was decided to diamond drill the Crean Hill
section before proceeding to minirg. These borings, the management states, revealed the
pre.eei ce of a body of high-grade copper ore along the foot wall. On the opposite or
hanging-wall side, as it is usually <lcsignated (although no hanging wall exists), and
beyond what was at lir.-it supposed to be the economic limit, there were irregular patches
of nickel ore quite different from that on the foot wall, and extending for over 200
ft. into the hanging. The mine, in the first stages, was developed with a view to
removing only the high-grade cojjper ore along the foot wall, which is fairly regular
and well defined. Subsc(|uent developments, however, indicated that these apparently
isolated patches of nickel ore were in reality continuous, enclosing masses of rock
and usually not intimately mi.xed with the rock. The question then arose, how to
win this nickel ore at an economically reasonable cost. It was evident that, in order
to separate the ore from the rock with which it is so intimately associated, it would
be necessary to break up the entire mass, the problem, of course, being to dispose
of the rock conveniently and cheaply. To meet this situation was Mr. Lawson'3
objective. A brief description and sketch are given of the methods now employed
by him to this end.

At each level the ground is cut into blocks by exploratory drifts (below the oth,
125 ft. apart), laid out as regularly as possible and carried to the boundary of the
mineralized section. Wherever an enrichment occurs, these drifts are widened and
raised to a height of about 35 ft., and then carried as breast stopes. These breast
stopes are advanced by first taking a cut out at the floor (about !) ft. deep), setting
up the drills on the muck and slicing with wet holes until the roof is reached. A
cu: is then taken out at the back; the drills thereafter being set up on bars, the cut
dei'pened and the stope carried underhand to the floor. The face being then squared
up, the bottom cut is again in order. By this means no staging is required, and the
work is carried on regularly and continuously. \t the floor level, the richer por-
tions only are removed, so as to avoid handling rock, but on the back stopes, where
the rock can readily be disposed of, pretty much all rock containing mineral is broken
and handled, except the very large masses which are left as pillars, care of course
being taken to maintain pillars in position to support the ground. Until sufficient
space has been provided, all rock, as well as ore, must be hoisted, but, as soon as
practicable without hampering work at the breast stopes, the rock is piled up along
the walls. Masons are then employed to build the dry stone walls, which take the
place of drift sets to maintain the tramways. The walls are built about 4 ft. thick,
and 7 ft. high, reinforced at intervals with round timber. These walls are stronger
and not more expensive than drift sets. In the walls are built ore chutes and man-
ways. The latter commerce at the floor, are rectangular in form and large enough to
admit a tram car. In them are placed ladders and drill chutes. The ore chutes are
built up solid to the bottoms, which are formed of wood, lined with steel or cast-iron
plates. They are built circular in form above the roof of the drifts, which, where
manways and chutes occur, are about 12 ft. high. Ihe main tramways are double
tracked, covered with round tamarac or pine lagging. No effort is made to fill to the

THE CANADIAN COIM'KR CO.

2")

top of the walls with rock from the breast stopes, the deficit being supplied by return-
ing through chutes provided for the purpose, waste rock from the surface, all rock
hoisted direct or rejected in the ore house being returned to the mine.

The first lill is made lo within H or In ft. of the back, and is carefully leveled
oflf with crushed rock from the surface to form a smooth floor. Back stoping is
connnenccd on top of the till by slicing and raising until the back has reached a
height of 155 to 40 ft. above the tilled floor. While the stopes above the tills arc
designated "back stopes," they are in reality breast stopes, with the bottoms cut
away. By this means, maximum footage is attained by the drillers, and maximum
tonnage from the drilling.

A Creighton Stope, all in Ore.

The drilling is performed on bars, on top of the muck, and the drill holes, after
the proper height has been attained, are nearly all underhand, or wet holes (the
latter a very important advantage in such hard ground). The roof is easily accessible
for scaling and but little delay occurs after blasting, before the machine men can
again start to set up their machines. The trammers also can begin work promptly
at the beginning of the shift. On a new fill considerable waste of fine ore is inevi-
table, but, by dropping a slice 30 ft. thick, and handling it on one floor, the waste
is minimized.

()R(!ANIZATION AND EQUIPMENT OF

INGENIOUS AIR-OPERATED GATES ON CHUTES.

Some care i III engineering is required to provide convenient dumps for the rock
rejected on the back stopes. With this object in view the stopes are carried one
ahead of the other (i. e., one higher than the other), in the form of terraces, the
stopes being advanced in opposite directions to the fills, the reject of one stope
forming filling for the succeeding one. The ore-bearing rock is transferred from

Air-Operated Chute Gates.

the chutes to the tram cars by means of air-operated gates, devised by the manage-
ment (see illustration). The gate is hung radially to the lip of the chute, on a
square shaft placed underneath the bottom of the lip, and held in position by means
of arms which are integral parts of the gate. The bottom of the dip is about 1 ft.
above the side of the tram car. When the gate is open it swings under the lip.
The stream of ore flows into the car until it blocks. The car is filled to its full
capacity, heaped up, but no overflow occurs. The air is turned on and the gate cuts

THE CANADIAN COI'PKIt CO.

through the pile of coarse rock, separating the rock in the car from that in the
chute. No adjustment of the load is necessary. No delay occurs. Unless the chute
happens to be blocked, the whole operation of loading does not consume one minute.
Tram cars and skips each have a capacity of three tons, both designed to run con-
tinuously and withstand the excessive hard usage to which they are subjected. The
tram cars are designed and built on the premises. They are models of strength and
utility, the trucks being practically dirt proof and the bodies thoroughly braced.

NOTHING BUT OKE AT CREIGHTON FOR FILLING.

In all levels of the Creighton mine below the third, and all of the western part
on all levels, the method of mining is similar to that at Crean Hill, except that the
walls and filling consist entirely of ore. By this means a large reserve of broken
ore is always available in case of shortage of labor or a sudden demand for increased
tonnage. The latter emergency was met last winter by withdrawing filling from
part of a stope in which sloping had been completed. In this connection it may be
stated that these sloping operations at the Creighton are an object lesson in point
of economy and effectiveness. In one stope now being carried toward the surface
by Mr. Lawson — provided it is not drawn on too heavily in the meantime — there will
be approximately 1,000,000 tons.

BONUSES FOR EMPLOYES.

To accomplish this where you have scattered areas, so much handling and haul-
age by two or three railways, involves the closest supervision of cost. The system
employed at Copper Cliff is as thorough as the economies inseparable from such
ores make it imperative. Nothing is done without being threshe<l out by the depart-
ment chiefs, periodical councils and free discussions being the effective means
whereby best judgments are obtained. Whether it be in supplies, repairs, foundry
work or new plant — a great deal of which is produced in the company's shops on
the premises — the accounting is most business-like. Efficiency is the basis upon which
the equipment department is maintained. Underground or at surface there is a record
and comparative data for every item of expenditure. Drillers are bonused for reg-
ularity and footage in excess of a fixed minimum, runners and helpers .sharing pro-
portionately. This prize-giving is not confined to mines, however. Those crews
engaged on the furnaces are induced to make tonnage. As a consequence a maxi-
mum of output is secured with alacrity, and there is no quibbling by walking dele-
gates. Union and non-union men are given employment without discrimination. There
are 105 men employed in the machine, blacksmith, pattern and carpenter shops. On
transportation 6 locomotive engineers, 6 firemen, 1 hostler and 4 wipers, 3 conductors,
7 brakemen and 17 trackmen are employed. Here it may be explained that the
company has 25 miles of tracks, a roundhouse full of locomotives, ample rolling
stock, etc.

MORALE OF THE PREMISES PRESERVED.

By promoting fellowship and loyalty among employes, the management has
created a settlement with a united purpose, and instead of doubts which prevailed
in the earlier years, there is harmony and determination. Only so many stores are
allowed. Schools and churches of divers denominations evidence the permanency
of the residents. There is no room at Copper Cliff for mischief-makers. When a
public building is needed the company provides it — and then taxes itself to pay for
it. Roughly speaking the company provides three- fourths of the taxes. Residences

ORCJANIZAT'.ON AND KQUII'MENT OF

and living quarters arc made attractive, and at reasonable rentals. There is a club
house and hospital that ininht well serve as a nvulel for many Canadian municipali-
ties. Two skilled physicians are retained at Copper Cliff and one at each of the
mines, together with a corps of trained nurses. Modest charges are imposed for
treatmetit, there is up-to-date surgical e(|uipment, an«l a dispensary at which either
one of the physicians is in almost constant attendance. So that nothirg is left undone
to promote ihe comfort, health and sanitation of the community.

There is no need for reiterating routine mining features. The Canadian Copper
Co. for years deemed it good policy to work its larger areas, and defer the numerous
properties touched in the earlier year, until there were broader nickel markets, and
perhaps, lower treatment charges. The Lady Macdonald or No. 4 section, is soon to
be tested by diamond drilling. It is expected that a large body of ore will be revealed
as the formation bears a remarkable resemblance to the I'rood or No. 3 property,
where diamond drilling has shown a very extensive deposit. Perhaps it would be
unreasonable to expect to find two or three Creightons, and two or more Crean
Hills, and No. 3's ; yet there is nothing to prevent tonnage in quantity being obtained,
even though quality requires sorting. Thus far there is but one Creighton on the
fields, with clean ore and the grade that makes for snug profits. The Crean Hill ore
has to be sorted and the facilities for this arc simply effective. The rock house is
substantial and convenient, chutes, crushers, and trommels being so compactly installed
that a few men take care of the tonnage raised. Most of the sorting is done under-
ground.

LATEST ADIITION TO ORE RESERVES.

No. 3 mine, north from Sudbury, is one of the greatest assets in nickeldom. For
a distance of 3200 ft. bore holes were put down at intervals during the past year or
two. The management was confident the gossan outcroppings would not be so strong
unless there was substantial reason for it. In all '21 holes on the ridge have proved
an ore section that will of itself supply material for years. I was privileged to inspect
the core sections— the holes averaged 500 ft. deep. The grade is not that of
the Creighton or the Crean Hill. It can easily and at slight cost be brought up to
4%% of combined metal. Doubtless it would be unremunerative to sort it closer, more
especially as the contour lines of the section will make low mining costs a certainty.
If we allow for waste rock— the section is stratified and simplifies sorting— and take
1000 ft. vertical as an average of the ore in the section, and 8V6 cu. ft. to the ton, the
boring already indicates a grand total tonnage in the property of 35,000,000 tons.
Presently Capt. Lawson proposes to further block out the area by means of more
bore holes. When this has been done a railway will be built across lots to Copper
Cliff, three miles distant. No. 3 mine, therefore, with the estimated 5,000,000 reserve
at the Creighton, the reserve at the Crean Hill and the odds and ends elsewhere, some
of which may have other agreeable surprises, materially contributed to the potentiali-
ties of the company.

CHAPTER III.

METAILURCY AND EQUIPMENT.

Ores so complex as those of the Sudbury district, Ontario, and with their mar-
gins of profit contingent on special markets, inevitably throw the burden of proof
upon the metallurgist. Capital was provided for every phase of the progressive and

TIIK CANADIAN COIM'KU (X).

perplexing movement— the snittary exception beinn that in the early clays there was
a moment when the Ohio people felt it would he better to shut down. What metal-
ItirKii'al fxicllfiKj- thtrc has been at Copper Cliff and tho Orfnrd Works has In-en the
result of patience and thoroughness of practice. David II. Mrowiie, chief of the metal-
lurgical «lepartment at Copper Cliff, is a long way from being satisfied with the degree
of success attained. The management is maturing plans for basic hearth converters,
by the aid of which it is expected to smelt the green ore direct from the mine. That
would be an important economy. MoncI metal is to be ,{iven a wider range of applica-
tion. If the final separation and refining of th: R!*!"!* cannot be a> cheaply effected
in Can-'dn. as it i in the States, there is satisfaciion in the knowledge thai the malic
as shippe<l across tiie br)rder is not far removed from refinement. It is just snthcicntly
unrefined to be admitted free of duty to the United States.

The routine piirsi ed in the mining and metallurgy of the nickel-copper ore is of
most interest to the scitntist. .As it comes from the mines the ore is crushed and sized
in the rock houses, ap|)roximately to .'l-in. pieces. It is hauled to the roast yard. Us-
ually it preserves the h.irmonies between the mining and metallurgical chiefs if
there is a half year's ^tinp'y of roasted ore, or ore in process of roasting, upon the
heaps ready for the funi.'ce, . .\t Cojjper Cliff this heap roasting is an institution that
may not be altogether coii'liicive to comfort or the cultivation of lawns. Sulphur
fumes are unpleasant to those with sensitive olfactory nerves. None the less is the
roasting an essential preliminary. When this detail has been obviated the Copper Co
will have effected an economy of far reaching influence, because not only does it
involve added handling expenditures, but it locks up money for several months before
the ores are put through the furnaces. By smelting green ores, as it is planned to do.
the action would be quicker and profits realized sooner.

The first step in the roasting is to lay a bed of split cordwood, 18 to 24 in. deep.
On this the ore is piled to a depth of (I to 7 ft., the ratio of fuel to the ore being
as one cord is to each 'J5 tons of ore. In the smaller heaps, where a quick roast is
sought, the ratio is one cord of wood to 20 tons of ore. It may as well be explained
that the object of the roasting is to oxidize as much ( f the iron as possible, and also
to reduce the sulphur. As a rule, about one-half of the sulphur is eliminated. Im-
perfect oxidization of the iron is undesirable, as it leaves too much of the sulphur
going to the furnaces, thereby retarding the treatment. On the other hand, it is
anomalous that if too much sulphur is eliminated and the iron more perfectly oxi-
dized in the roasting, the smelter slags will be too high in nickel and copper.

Roast heaps now contain from 800 to 1000 tons. A quick roast may be obtained
in three months, although a better one will be had with a heap of 3000 tons roasted for
9 months. The time varies according to the size of the heaps, which it is the practice
to cover with G or 8 ins. of fines. After the pile is fired the combustion of the sul-
phur provides the necessary heat for the operation. Though crude, therefore, these
heaps have their advantages, except in wet weather. The loss in sulphur is grievous
Academic gentlemen have declared that this should not be. It would be hazardous,
however, to borrow trouble and money to save sulphur in that northern latitude, not-
withstanding the company would be willing to have the by-product, if it could sec
its way clear to obtain it without undue risk.

When ready, the roasted material is lifted by steam shovels. It is hauled in
50-ton drop-bottom cars to the ore house, a structure 35 by 600 ft., where there is a
double row of bins or pockets, 120 in all. Usually about 2000 tons of roasted ore is
on hand; also 1000 tons of green ore from the Crean Hill mine, with perhaps 1000

OHdANIZATlON AND Ktilll'MKNT ()l

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TIIK CANADIAN roiM'KU Co.

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oncJANIZATION AXn Kgril'MKNT OF

Ion* of ilnK nnil n-riip iiwaitiiiK rriri'atim-nl, bvniilcii the (|itarti, clay, coal, cokr and
limrxlonr, ii*ri| in thr rharRri.

Initnriliatt*!)' Iiclow tlu- liinn anil |)<K-kt*iii nro curvrd niinr KUlr* fnin) whirh the
charKc cars arc iDuilvd. I'lMir trains nf H cart each containiiiK the rharK<'<«, arr
haiile'l Ity i-lcrtric motors to the furnacei AlHutt 7 ton* make a charxe, along with
which thrre in II Ik \'i'/r coke, which ix ftil timl to the ftirnnce*. The chnrne varies
CreiKhtrin ore re(|nires silica; Creun Hill ore HiMnetimes needi lime. An average
train Koing to the furnaces coniitti of Ti tons of roasteil ore, 1 ton of quartz, I ton of
Crean Hill green ore, I Ion either of scrap from the furnace, or slag, and odds and
ends cleaned up in the smelter, l-'.ach car is weighed. The weight chocks against the
output nf matte. The trains are operated on a douhie-track oval al)uut mie third of a
mile in circumference. They pass on each side of the five furnaces, thus enalding
the crews to dump them tlirect into cupolas, to <lo which takes about live mimites.
Every 'Jn minutes the charge is repeated. It is an unwritten regulation of the man-
agement that the furnaces are to he kept going perpetually, and at all rea.sutiahh*
hazards, l-'or that matter the entire arrangement ai ns at continuity and consecutive-
ness. Mr. Browne has learned the lesson that, while carrying a fixed charge, certain
variations in the silica and coke must lie left to the ju<lgment of the foreman, and
that local variations in the ore, and the working of the furnaces, must he left to that
common sense which is a factor of experience. One of the most interesting exam-
ples of how thoroughly the various departments co operate is ohservalile in the pipe-
cooled jackets used in the furnaces. The detail was entirely worked out in the Cop-
per C'o.'s shoj)s, and the result is a furnace which has the attraction of novelty and
the merit of practical utility.

The furnaces are set on M ft. of concrete on a tap platform. The blast is supplied
by 'V2 tuyeres, and the air supplied weighs three times as much as the ore and Huxes,
The furnaces are .V) by 201 ins. at the tuyeres, and they ci>nsist of three tiers ,)f water
jackets, the lower, the tuyere, being cast iron, forming together one jacket, M ft. (I ins
high. The upper, or top jacket, tl ft. in height, is made of plate iron. Each of the
tuyere jackets contains two ti-in. tuyeres. The side tap is notched out of one of the
middle tuyeres on the crane side, and is fitted with a water-cooled bronze side-tap
jacket, 10 by 24 ins. In the beginning, the ordinary copper furnace spout was used to
carry matte from the furnaces to the settler. As a result there were 32 separate
explosions at this spout, to say nothing of Mr. fJrownc's other troubles. This diffi-
culty now is obviated by a chrome brick water-cooled spout of local conception ami
design. It looks clumsy, but works beautifully.

Each of the settlers is Iti ft, in diameter and 5 ft. high. The slag flows oflf at the
back of the tap platform into pots. This slag carries about one-half of 1% copper-
nickel. The matte is tapped out at intervals, 5 to 7 tons being taken at each tapping.
This is known as furnace matte and contains 30 to 35% copper-nickel. As the matte
has been tapped into ladles two tracks are provided upon which the ladles are hauled
by motor some 75 ft., to the converter building, where the converter crane picks them
up. The delivery of the ladles and their contents to the respective converters, of
which there are 10, is controlled from the two converter cranes.

The converters in use are of the Allis-Chalmers type, 10 ft. long and 8 ft. in diam-
eter. It costs about $000 per day to reline these when the converter plant is running
in full force. The lining is an ordinary mixture of white quartz and clay rammed
around a central core, the inside measurement being fi by t by 2 ft.

Blowing is carried on in exactly the same manner as for blister copper. The laity

TIIK CANADIAN ('(H'l'KIl CO.

may i-iii))|>r<liriiil lliin l)rtlrr witrn it i* ilntod that thr convrrtrr lookn likr an im-
niriixv liitrrt'l liiid <>ii iii niilc on roller*. At tlu' Uiuk nf tjic liiirrfl ii mw of tuyeret
or pipri, ailiiiii the air, at it wrrr, nlotiK mtc itavc of the barrel. When matte ii put
in ihr roiurrtcr, air '\* tiirtifil mi and |iaii*ii'K ihrnnKh the matte liiirnit the iron, which
unites with the (|iiart/ in the linitiK to form hUik I liit xloK i* (Minred otT from time
to time. In niKuit two hotiri the iron in all hnrned out and the matte, which cont lincd
;tO t.i l.i' ; iTiital at the start, now contain HO'X. This is the final proiluct— Heuemer
ttiattr .\lr. Itrowne, it may here lie said, has recently presented a most interesting
li;i|KT on the liehavior of copper-nickel matte in the llessenur converter, pulilishetl in
the transactions of the .American Institute of MiniiiK KiiHiiu-ers. "Cons, lering," he
says, "the lie.it of formation, nickel would lie expecteil to follow the iron easily anil
completely into the slag. Instead of doiiiK xo it displays a most extraordinary reluc-
tance to part from the cupper, the two metals clinginK toKether in a deathless affinity
— so nnich so that 1 lli. of nickel p.i'Hsiin; into shm drans l.'J'i llis. of copper v/itli it."

iCxaniiniiiK carefully the work done on copper conversion, and compariiiK thii
with The Canadian Copper (.'o.'s matte, it is found that copper nickel ffirmn an alloy
in the converter, which resists oxidation until all of the iron has heen Mown out of
the matte. This alloy is Monel metal, and the action of Monel metal in the con-
verter follows exactly the laws that copper follows duruiK the Mow The two metals
act together, no matter what the proportion he, high copper and low nickel, or vice
versa; they present in conversion the same curious resistance to oxidation, and their
relations toward iron are alisolutely similar to the relations of copper alone. This
alloy, or Monel metal, contains aliout 70% nickel and ;»()% copper.

The proportion is very nearly that in which the two metals exist in the ores
of The Canadian Copper Co. and liy careful attention to the furnace charge a Besse-
mer matte can lie produced within I'/r of that required in makiiiK Monel metal. "The
matte is Mown," Mr. Browne explains, "till the iron is eliminated, the sulphur is
removed liy roastiiiK, and the coniliined oxides are reduced to metal. As the combined
metals have never lieen sejiarated from e.nch other the particles of each seem to be
in more intimate contact than can be attained by any synthetic method of manufac-
ture. It seems incredible, but it is a fact, that nutalhirKists have not been able to
produce by meltiiiK copper and nickel toffctber, an alloy having the same physical
properties as the alloy produced direct from the matte."

It is hardly necessary to elaborate beyond this the action within the converter
during the two hours devoted to the burning of the iron to iron oxide. That oxide
grabs th • silica. United thsy make the slag. Those supervising the converters deter-
mine the extent of the elimination of the iron by the gradual clarification of the
green tiamc. When the bright flame shows that the nickel has begun to slag,
the converter is turned down and the matte is cast into a ladle from which, in turn,
after being shifted by the traveling crane, it is poured into molds in the shed adjoin-
ing the converter building. The matte contains about 80% copper-nickel, 17% sulphur,
antl %% of iron.

Meanwhile the slag from the settlers has been taken to a "merry-go-round," a
circular steel framework 58 ft. in diameter, on a circular track. On this framework
rest cast-iron molds forming a continuous flat ring. Each mold is 12 by '10 by 4 ins.
and holds about 150 lbs. of slag. This ring is slowly rotated under the stream of
slag being poured from the pots. The slow rotation allows time for the slag to cool
before the molds reach a hand-controlled tripper, which reverses the mold and drops

■

OHC.ANIZATION AND KCil'IPMKNT OK

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the matorinl intu a liupiii-r. lU'low iliis Imiipir is a iiiitR- skip that carries the slagf
up an incline track and drops it into a steel bin of TttHl tons capacity above the cliarging
tracks.

KIN.M, AITION .\T TlIK ORI'OKIl W'OHKS.

A nhmce hack at what has to ha|)pen before the matte reaches its final destination
will carry the conviction to the open-minded that Canada does not fare so hadly in
its share of the expenditures incurred in the mining and smelting of nickel-copper
ores. The spending money helorgs to Canada, and Canada gets it. Of course it
would lie ideal to have the relining done on this side of the border, were it not for
economic handica|)S and tariff imposts which would cripple the nickel industry. Tiie
hope is that Monel metal will be complete in itself and without further treatment find
a market. As such it would be a bulk product avoiding relining costs. Of its future,
Ex-Judge Wallace Nesbitt stated to a legislative conunittee: "If the conipany succeeds
in popularizing Monel metal, the results will be of greater benelit to Canada than any
other discovery, because we then can utili/.e the thousands of acres of the low-gradi
ores."

Briefly, the Orford process, as the court of last resort in the n fining of nickel, is
a chemical process con<lucted in a locality where there are sundry other scientilic
nuisances to which distance lends enchantment. The Orford Works are close to
chemical factories, and oil refineries. The coke an<l coal used there woidd cost three
times as nnich as if they were hauled to Sudburv or Copper ClifT, and then the assort-
ment of unsavory flavors would doubtless suggest that the Orford Copper Co. shoidd
be bonused to return to Hayomie. In the smelting at the refinery the quantity of coke
runs to about 4<l% and in the reverberatory work selected coal is necessary. In the
filial smelting of the nickel there must be a sulphur-free oil. Nickel cannot he smelted
or heated for rolling with a sulphur-bearing oil.

Refining consists, according to Orford practice, of several smeltings. Fir't there
is a smelting in a blast furnace with salt cake or sodium sulphate, the latter being
reducetl to a sulphide which forms, with the copper and iron sulphides, a fluid matte
of lower specific gravity than the nickel sulphide. A crude separation is the result
The material is cast in pots. On cooling, the "tops" or upper portion containinf{ iron
and copper sulphides with sodium sulphide and some nickel, and the "bottoms" carry-
ing most of the nickel with a small quantity o( iron and copper, are easily separated
by the blow of a hanuner. Then the retreatment of the "bottoms'* begins. They are
mixed with fresh salt cake and re-smelted, and the sulphide of soda liquates the
copper from the nickel present, allowing the nickel to go to the bottom as nickel sul-
l iiide. llventually, by means of careful adjustments, a pure sulphide of nickel
is obtained. There are leachings with acids and Henderson roasts to eliminate the
iron, copper and cobalt and a tinal reduction with charcoal in a reverberatory. The
copper "tops," which contain 5 or (•% nickel, are re-melted in a cupola, and taken to
a Oessemer converter forming blister copper, which is sent to the electric refinery.
The copper slags go back to the matte cupolas. Altogether the metallurgy of the
separation of nickel and copper is one of the most complicated problems in modern
practice.

COMPREHENSIVE PI^NTS AND POWER SYSTEM.

This narrative would be incomplete without a chapter on the permanency of the
plans following on the formation of the International Nickel Co., which made possible

ORGANIZATION AND EQUIPMENT OF

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metallurgical works and power plants costing $4,0(M),')00. No better illustration of the
evolution of the nickel industry can be offered than this :

East smelter started December, 1888.

West smelter started Deccmhcr, 180!).

New smelter started July, 1!M»4.

Power rights obtained on Spanish ri\ ■, 1904.

Power plant provided on Spanish river at cost of $750,000.

Practically 10 years elapsed before The Canadian Copper Co. was in shape for
large business. Given exemption from local prejudices and export duties, and having
a measure of official sympathy, after the organization of the International Nickel Co.,
The Canadian Copper Co. was free to consummate its plans for the modernizing of
its plants. Today the buildings al Copper Cliff may thus be summarized;

Laboratory, 40 by 80 ft.
Sub-station, 8,') by 104 ft.
Furnace building, 8.5 by ,375 ft.
Converter building, 95 by 522 ft.
Furnace shed, 32 by 295 ft.
Steam power plant, 104 by 160 ft.
Sample house, 30 by 50 ft.
Ore bins, 35 by COO ft.

Warehouse. CO by 150 ft.

Foundry, 36 by 98 ft.

Car and carpenter shop, 60 by 154 ft.

Pattern storage, 30 by 84 ft.

Machine shop, 72 by 154 ft.

Hoiler shop, 60 by 98 ft.

Balloon flues, 20 by 472 ft.

The identification of Messrs. Schwab, Monel, Thompson, Converse, Wood, De-
Lamar, and others of prominence, and the gi'^atest influence in the industrial world,
lent substance to what already had been aci oniplished. Instead of make-shifts at
Copper Cliflf and throughout the areas controlled, there are all the facilities science
and capital could provide. President Turner of The Canadian Copper Co. stated the
case to Ottawa legislators when he said that during the 15 years previous to the Inter-
national Nickel Co., the works at Copper Cliff had grown, furnace by furnace and
shed by shed, until in 1902 they consisted of a series of "dilapidated wooden build-
"jigs covering a lot of antiquated machinery, entirely unadapted to future expan-
sion. By contrast we have Mr. Turner's present day view that the Copper Cliff
smeller is "the most up-to-date of its kind in the world." Experts who have been
privileged to visit the premises coincide with Mr Turner's view. Electric power
came into general use, and for the first time anywhi re, in that plant. Even the man-
agement has had to revise and enlarge its plans. "Realizing,' says Mr. Turner, "that
the plant was not large enough for curreii' developments, and believing in the future
of the nickel industry, the company in 1905 decided to again enlarge, making the
furnace building suitable for five larg ' ' naces, besides arranging for a separate
building con* iiip i.) ilessemer stand.', \v ,h a possible future capacity of 1500 tons
of ore per day. '

It had long ijeen cidont to the management that power costs were too high. In
1904 water-power rights, tlierefore, were obtained on the Spanish river — those rights
being vested in the Huronian Co., a subsidiary concern. At what is known as High
Falls there has been provided at a cost of $750,000, one of the most efficient plants
in the world, capable of supplying 12,000 hp. This cost covers transmission lines.

High Falls is located 4 miles or so north of the town of Nairn, on the "Soo"
branch of the Canadian Pacific railway, and about 28 miles from Copper Cliflf. At
High Falls the river flows on both sides of an island, 2000 ft. long by 900 ft., the

ORGANIZATION AND EQUIPMENT OF

center of which stands at an elevation of 7o ft. above the upper water level. Pictur-
esquely the spot is ideal; economically it could not be excelled for power purposes.
On each side of the island was a natural fall of 05 ft. The island, therefore, entered
into the plans of the engineers, Messrs. Ross & Holgate of Montreal. By cutting a
forebay on its east side and damming both channels, a total head of about 85 ft. was
obtained between the upper and lower levels. The raising of the water 20 ft. by this
construction forms a storage basin (i miles long. From 15,000 to 20,000 ft. of water
per second is going over the large spillway to the west, considerable of the surplus
not taken into the penstocks going over another spillway to the east near the forebay.

The water enters gates at the extremity of the forebay, thence to three penstocks,
9 ft. in diameter. There is an effective head of 85 ft., and the water is regulated so as
to enter the turbines at a maximum speed of 7.2 ft. per second. The power house is
a concrete and brick building, 100 ft. long by 71 ft. wide, in the main, with an exten-
sion 24 ft. wide along one side, and a wing .'JS ft. sq. at one end, containing a store-
house and repair plant. The power plant proper consists of three Crocker-Wheeler
generators of 3000 hp. each, direct-connected to 1. P. Morris twin-type turbines, each
served by one of the 9-ft. steel penstocks. There are two exciters of 275 kw. each
direct-coupled to a small turbine of similar design to the power turbines, and both
served by a common exciter penstock, 3 ft. in diameter. Each generator has its own
bank of three transformers. There are also a 5-in. 2-stage turbine fire pump, a
Westinghouse air compressor, a Sturtevant blower-heating system, and a Whiting
traveling crane over the machinery. Everything is distantly controlled by low-voltage
switches from an elevated pulpit, with a Westinghouse switchboard.

Usually only two units are in operation, one being held in reserve, and there is
space for a fourth. The machines generate 2200 volts, and the pressure is raised to
35,000 volts, at which tension it passes through the tower to the transmission line to
Copper Cliff, where it is again reduced to 2200 volts. At the moment the daily require-
ments are 4000 hp. The transmission line follows the "Soo" railway for about 29
miles to Copper Cliff, where it enters the sub-station, a concrete building.

At the sub-station are four Nordberg radial valve blowing engines.
These are rope-driven by Allis-Chalmers induction motors of COO hp. working at
2200 volts. The motors may be worked at three speeds. The engines are duplex,
42-in. stroke, 70-in. piston diameter, and they deliver 320 cu. ft. of free air per revo-
lution. The blast for the Bessemer converters is furnished at 12-lb. pressure, by a
Nordberg blowing engme, capacity 10,200 cu. ft. per minute, rope-driven by an Allis-
Chalmers-Bullock 500 hp. induction motor, running at a constant speed of 375 r.p.m. ;
also by an Allis-Chalmers blowing engine, capacity 20,700 cu. ft. of air per minute,
rope-driven by a 1200 hp. motor. For the air hoists on the furnace doors, for oper-
ating drills, and for similar mechanical work, a 110-lb. air-compressor (Laidlaw-
Dunn-Gordon) is provided, direct-connected to an AUis-Chalmers-Bullock induction
motor of 300 hp. The motive power for the electric locomotives, which take the
trains of ore from the ore bins to the furnaces, is furnished by a 100-kw. n^otor-gen-
erator set, which takes 550 volts, alternating current, and delivers 250 volts, direct
current. There are besides a Worthington turbine fire pump, a Sturtevant heating
blower, two banks of three each of Crocker-Wheeler transformers, three banks of
three each of Westinghouse transformers, a 50-cell Westinghouse storage battery, a
15-panel switchboard (Westinghouse), and two 10-ton Whiting hand-power cranes.
In addition to the electrical power there is an emergency steam plant, containing four
400-hp. boilers (Aultmen-Taylor), Snow feed and Snow hot- well pumps, two Nord-

THE CANADIAN COPPER CO.

berg Corliss cross-compound furnace blowing engines, one Nordberg Corliss cross-
compound converter blowing engine, two Robb-Armstrong tandem-compound steam-
driven generator sets, etc.

Wherever expenditure nuant economy the International Nickel orgnnixation has
sustained President Turner of the Copper Co. The Spanish river station and trans-
mission system was costly on capital account, but it is saving about $.'W0,000 per
annum as compared with former power items in the balance sheet. Power now is
being obtained for about $15 or less per horsepower-year, spread over all charges,
including cost of plant. Exclusive of capital charges the cost per horsepower year is
about $(), so that the Spanish river plant is useful as well as ornamental. There was
a time when power cost $125, $80 and $00, according to governing conditions. Going
it alone The Canadian Copper Co. might not so soon have projected the generating
plant at the price, to say nothing of all the other improvements following on the
amalgamation under the .Tgis of the International Nickel Co.

THE SILVER PLANT AT COPPER CLIFF.

The old Ontario smelter plant in which the Orford Co. tried to treat nickel-copper
ores in 1001, and which was partly burned in 1904, is now the site of works at which
the mine owners of Cobalt have received much relief. The present plant began
operations in 1904. It is not remarkable for its arrangement, but it has given results
which were welcomed by the silver mines whose ores were specially sought. Fully
a third of the silver from Cobalt has been accounted for at this Canadian copper
smelter. It is more convenient than the American metallurgical works, freights
are lower, the charges always have been regarded as comparatively favorable, and it
is felt that the competitive factor should be encouraged. In five years, therefore,
the silver recovered at Copper Cliff has been as follows :

Tona ore

Year. treated.

1905 205

1906 771

1907 2,286

1908 4,493

1909 5,361

13,116

Tons

Ounces silver

Average

Cobalt

arsenic

accounted for.

assay, oz.

bought.

shipped

234,700

1,145

16.4

....

1,117,900

1,450

53.9

201

3,903,200

1.707

143.0

330

8,553,000

1,748

305.0

489

8,824,630

1,646
1,539 Avg

331.0
. 849.3

622

22,633,430

1.642

To comprehend these figures it must also be understood that Canadian metal-
lurgical works all told, took 2585 tons of Cobalt ore in 1907; for example, 7401 tons
in 1908 and 10,230 tons in 1909; so that Copper Cliff retains its position as the
Canadian banker for Cobalt mine owners. Really it has had a sixth of the tonnage
from Cobalt, paid for more than a third of the silver, and it allowed something for
cobalt contents of 6% and over until the market for the oxide offered little hope for
future reward from the speiss.

The Cobalt plant is an adaptation, the tonnage of ore shipped from that camp
being so small that large installations could not be thought of. It has a daily capacity
of about 30 tons. The ore is conveyed from the cars to a weighing scale. There it
is stacked in 10-sack lots, and the gross weight ascertained. It is then put through a
Buchanan jaw crusher. Provided the ore is dry it is delivered directly to an Allis-
Chalmers ball mill, otherwise it is spread upon steam drying plates, and then it goes
to the ball mill. Meanwhile, as the ore came from the jaw crusher, a small shovelful

■^-T

ORGANIZATION AND EQUIPMENT OP

from each sackful has been set aside as a preliminary inoistiirc sample, reprcsciuing
the moisture contained in the ore as shipped. These samples are coned and carefully
quartered to about 20 lbs., after which they arc taken to the sampling room. The ore
passes from the ball mill into a Snyder automatic sampler. It is calculated that 20%
of it will pass a 20-mesh, that 40% of it will pass a lOO-mesh screen, and 40% a
50-mesh screen. The nietallics remain in the ball mill. After the run is completed
they are removed, weighed, melted and run into bars. The speiss and the slag from
these are combined and sampled together, while the bullion is sampled separately.
In going through the Snyder sampler one-tenth of the milled product is automatically
cut out. The sampler takes TjO samples per minute or 00,00!) per carload of HO tons.
The adjustment by which the cuts are made is regulated by a chain <lrive which pre-
vents slipping. The pulp is delivered through a spout so as to fall inside of a sloping
flange, shaped somewhat on the principle of a miner's pan, but having four openings
in the flange, which revolves at the end of a horizontal shaft. Two of the openings
are closed. The other two take the samples as they fall from the spout and imme-
diately discharge them each revolution, of which there are 25 per minute.

The milled product, less the percentage automatically sampled into a sample
chamber, is weighed and goes to storage bins. The bulk sample amounting to 10%
of a 30-ton car is taken from the chamber and weighed, so that the sum of what is
in the storage bins and the bulk sample becomes the basis of settlement, less the
moisture, after the customary quartering, coning and drying. The whole sample is
coned and systematically quartered down to a 20-lb. sample, dried overnight, and in
a Braun grinder ground to pass a lOO-mesh screen. The original sample from the
ore as received is similarly dealt with, until the metallic scales in each instance are
left clean and bright on the sieve. The routine of this has been described by A. A.
Cole, who held that the methods employed were "exceedingly good practice" and that
"the final samples should be about as close to the truth as it is possible to get them."

In the subsequent treatment of the ores the main difficulty is in getting rid of the
arsenic. It is eliminated in roasters. Not all of the ores are put through, however,
as a good deal depends upon the amount of sulphur and silica. Some of the ore is
given a straight roast. The arsenic is drawn off to condensing chambers, of which
there are 96, thence to a sublimer and passed on. Subsequently teachings of the
speiss are dealt with for arsenic in order to avoid accident to cattle.

Otherwise the process of separation of the metals does not differ materially from
the furnace practice in the average smelter. The slag is tapped, and the speiss and
silver are drawn off twice an hour, according to the grade of ore. The bullion
obtained is 90% pure silver. It is melted with a little lead into bars. The speiss
usually carries about 1200 oz. of silver to the ton, 25% cobalt, 18% nickel, 32% arsenic
and 15% of iron. It is reground, roasted and leached so as to get a lower iron
content.

In regard to the work at the Cobalt plant, the management has just received the
approval of the directors of the company to make certain changes by which it will
be enabled to treat 800 tons of ore per month. It is planned to install a silver refinery
o that the company will ship both refined arsenic and refined silver. At the same
time it will ship crude cobalt. It should be explained that there is no refined cobalt
made. It is always produced in the form of an oxide or hydrate so that when
shipped it will really be a refined product as it will be in the form that the cobalt
users purchase.