The Falconbridge nickel smelter operated two 9by 30 m electric furnaces from 1978 to 1994 without a majorrebuild. In July 1994, No.2 Furnace was upgraded and rebrickedto accommodate double the previous calcine treatment rate.No.1 Furnace was subsequently shut down. Rebricking includedreplacement of all side wall and end wall brick, with the roofand hearth remaining in place. Details of refractory coolingdesign are presented in this paper. Milestones of the rebuildschedule are outlined, including cool-down, excavation,evaluation of the hearth, and the reheat schedule. Results duringthe first year of operation at higher capacity are discussed.
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