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Process Controller- Extractive Metallurgy

Curriculum DocumentCurriculum Code Curriculum Title

313912-004 Mineral Beneficiation Process Controller: (Extractive Metallurgy)

DRAFT CURRICULUM – JUNE 2014 Page 1

Occupational Curriculum - Jun 06 - 2014 - 09:20:11 1 of 84


Table of ContentsSECTION 1: CURRICULUM OVERVIEW.......................................................................................................................1

Occupational Information.............................................................................................................................................1

Associated Occupations...........................................................................................................................................1

Occupation or Specialisation Addressed by this Curriculum....................................................................................1

Alternative Titles used by Industry...........................................................................................................................1

Curriculum Structure....................................................................................................................................................3

Knowledge Subjects.................................................................................................................................................3

Practical Skills Modules...........................................................................................................................................3

SECTION 2: OCCUPATIONAL PROFILE.......................................................................................................................5

Title: Mineral Beneficiation Process Controller: (Extractive.........................................................................................5

Metallurgy)...................................................................................................................................................................5

OFO Code................................................................................................................................................................5

Occupational Purpose..............................................................................................................................................5

Occupational Tasks..................................................................................................................................................5

Task Details.................................................................................................................................................................5

TASK 01: Monitoring and controlling the extractive metallurgical processes..........................................................5

(NQF Level: 4)..........................................................................................................................................................5

SECTION 3: CURRICULUM COMPONENT SPECIFICATIONS SECTION...................................................................6

3A: KNOWLEDGE SUBJECT SPECIFICATIONS.......................................................................................................6

313912-004-KS-01: Extractive Metallurgy...............................................................................................................6

Provider Accreditation Requirements for the Subject:.............................................................................................8

SECTION 3B: PRACTICAL SKILL MODULE SPECIFICATIONS...............................................................................9

313912-004-PM-01-Monitor and control the milling and separation processes (NQF Level: 4)............................10

Provider Accreditation Requirements:....................................................................................................................12

313912-004-PM-02-Monitor and control the gravity processes (NQF Level: 4)....................................................12

Provider Accreditation Requirements:....................................................................................................................13

313912-004-PM-03-Monitor and control the thickening processes (NQF Level: 4)...............................................14

313912-004-PM-04-Monitor and control the filtration processes (NQF Level: 4)..................................................16

313912-004-PM-05-Monitor and control the leaching processes (NQF Level: 4)..................................................17

313912-004-PM-06 Monitor and control the agitation process (Credits: 5)...........................................................19

313912-004-PM-06-Monitor and control the froth flotation processes (NQF Level: 4)..........................................20

313912-004-PM-07-Monitoring and controlling the adsorption processes (NQF Level: 4)....................................21

313912-004-PM-08-Monitor and control the elution processes (NQF Level: 2)....................................................22

313912-004-PM-09-Physically monitor the make-up, storage and distribution of reagents (NQF Level: 8)..........25

SECTION 3C: WORK EXPERIENCE MODULE SPECIFICATIONS........................................................................26

313912-001-WM-01- Exposure to the full extractive metallurgical mineral processes..........................................27



SECTION 1: CURRICULUM OVERVIEW

Occupational Information

Associated Occupations

Mineral Beneficiation Process Controller

Occupation or Specialisation Addressed by this Curriculum

Mineral Beneficiation Process Controller: Extractive Metallurgy

Alternative Titles used by Industry

Plant Operator



Curriculum Information

Relation of this Curriculum to the Occupation and QualificationProgression

Notes Regarding the Progression:

The qualification covers the work executed by the “inside and outside” process controllers, the learning covers both NQF level 3 and 4 learning material and the qualification is pitched at NQF 4. This qualification builds on the entry level qualification “Process Controller: Materials Handling” and will build the competence of learners to execute the work of a process controller in a Mineral extraction facility. It will enable the learner to gain the knowledge, develop the skills and be exposed to the work experience required to work in a process plant and to monitor and control all processing equipment. Learners will gain the knowledge, skills and experience to operate plants in a safe and efficient manner and to apply the required communication skills unique to working in a processing plant environment. Learners will also learn all the basics of equipment start up, shut down and operational monitoring from a physical (in the plant) and from a control room perspective. This qualification will provide learners with a portable qualification that they can apply in any extractive metallurgical process.



Curriculum Structure

Knowledge Subjects

Number Title NQF Level Credits

313912-003-KS-02 Extractive Metallurgy 4 25

Total Knowledge Credits: 25

Practical Skills Modules

Number Title NQF Level Credits313912-004-PM-01 Monitor and control the milling and separation processes 4 4313912-004-PM-02 Monitor and control the gravity processes 4 2313912-004-PM-03 Monitor and control the thickening processes 4 3313912-004-PM-04 Monitor and control the filtration processes 4 4313912-004-PM-05 Monitor and control the leaching processes 4 4313912-004-PM-06 Monitor and control the froth flotation processes 4 6313912-004-PM-07 Monitor and control the adsorption processes 4 5313912-004-PM-08 Monitor and control the elution processes 4 5313912-004-PM-09 Physically monitor the make-up, storage and distribution of

reagents4 4

Total Practical Skill Credits: 37

Work Experience Modules

Number Title NQF Level Credits313912-002-WM-03 Exposure to all the sections in a extractive metallurgical mineral

processing facility4 60

Total Work Experience Credits: 60

TOTAL QUALIFICATION CREDITS: 122Knowledge Percentage: 20% Practical Skills Percentage: 30% Workplace Percentage: 50%

International Comparability



Entry Requirements



SECTION 2: OCCUPATIONAL PROFILE

Title: Mineral Beneficiation Process Controller: (ExtractiveMetallurgy)

OFO Code: 313912-003

Occupational PurposeOperate, monitor and control the operational efficiency of extractive metallurgical beneficiation process and the processing equipment

Occupational Tasks

TASK 01: Monitoring and controlling the extractive metallurgical processes(NQF Level: 4)

Task Details

TASK 01: Monitoring and controlling the extractive metallurgical processes(NQF Level: 4)

Unique Product or Service Raw materials processed

Occupational Responsibilities

Monitor and Control the physical separation processes Monitor and control the milling and classification processes Monitor and control the gravity and

centrifugal processes Monitor and control dense medium

separation Monitor and control the liquid/solid

separation processeso Thickeningo Filteringo Settlingo Counter current decantation

Monitor and control the electrostatic precipitation processes

Magnetic separation

Monitor and control the hydrometallurgical Extraction processes Monitoring and controlling the chemical separation processes

o Precipitationo Distillationo Adsorptiono Crystallizationo solvent extractiono hydrolysiso Chemical reduction



Monitor and control the elution processes Monitor and control the leaching processes

o Monitor and control bacterial leaching process Monitor and control the regeneration process Monitor and control the electro winning processes

Monitor and control the milling and separation processes Monitor and control the gravity processes Monitor and control the thickening processes Monitor and control the filtration processes Monitor and control the hydro

metallurgical processes (Which may include one or more of the following)

o Monitoring and controlling the adsorption processeso Monitor and control the froth flotation

processeso Monitor and control the elution processeso Monitor and control the leaching

processeso Monitor and control the regeneration process

Physically monitor the makeup, storage and distribution of reagents

Context Exposure to the milling and separation processes Exposure to the thickening

processes Exposure to the filtration

processes Exposure to the leaching

processes



SECTION 3: CURRICULUM COMPONENT SPECIFICATIONS SECTION

3A: KNOWLEDGE SUBJECT SPECIFICATIONSList of Knowledge Subjects for which Specifications are included

Number Title NQF Level Credits

313912-003-KS-02 Extraction Metallurgy 4 25

Total Knowledge Credits: 25

313912-004-KS-01: Extractive Metallurgy

Purpose of the Knowledge SubjectThe focus of the learning in this module is on building the learners understanding of the key theories, concepts and principles required to monitor and control an extractive metallurgical ore beneficiation process.

Topics included in this subject:

TOPIC NUMBER TOPIC TITLE WEIGHT CREDITS313912-004-KS-01:01 Tailing/waste disposal processes (Basic) 6

313912-004-KS-01:02 Principles of the various chemical processes and interactions that take place in an extractive metallurgical process (Intermediate)

16

313912-004-KS-01:03 Metallurgical principles of mineral extraction using different techniques (Intermediate)

TOTAL TOPIC CREDITS: 22

313912-004-KS-01:01 - Tailing disposal processes (Basic) (Credits: 3)

Topic Elements to be covered include:1. Identify the different types of tailings and describe the various methods of recycling or storing tailings;2. Explain the environmental considerations and related regulatory requirements when dealing with tailings;3. Describe the various processes for neutralising chemicals in tailings;4. Describe the key parameters of tailings and indicate why these parameters are important (density etc);5. Describe the process and importance of water management when dealing with tailings;6. Identify and describe the use of the equipment required for the safe and efficient recycling and storage of tailings;7. Describe the operating principles of tailings dams and indicate how this impacts on the position of depositing tailings into the dams;8. Describe the impact of pumping distances on the effective transfer of tailings material into a tailings storage facility.

Internal Assessment Criteria:



313912-004-KS-01:02 - Metallurgical principles of mineral extraction using different techniques (Intermediate) (Credits: 16)

Topic Elements to be covered include:1. Describe what the various chemical processes are (Dissolving, Concentrating;Precipitation; Calcination; Neutralising; distillation; adsorption; elutriation);2. Explain the interaction between the various processes;3. Identify and explain the sampling analysis parameters for each of the products after each chemical process;4. Describe the main deviations from standard and indicate what must be done to rectify them;Monitor and Control the physical separation processes

Monitor and control the milling and classification processes Monitor and control the gravity and

centrifugal processes Monitor and control dense medium

separation Monitor and control the liquid/solid

separation processeso Thickeningo Filteringo Settlingo Counter current decantation

Monitor and control the electrostatic precipitation processes

Magnetic separation

Monitor and control the hydrometallurgical Extraction processes Monitoring and controlling the chemical separation processes

o Precipitationo Distillationo Adsorptiono Crystallizationo solvent extractiono hydrolysiso Chemical reduction

Monitor and control the elution processes Monitor and control the leaching processes

o Monitor and control bacterial leaching process Monitor and control the regeneration process Monitor and control the electro winning processes


313912-004-KS-01:03 -Metallurgical principles of mineral extraction using different techniques (Intermediate) (Credits: 3)

Topic Elements to be covered include:1. Explain what is meant by product separation and why this is important in the beneficiation process;2. Identify and list the typical equipment used in the separation process;



3. Define the basic metallurgical principles used in the separation processes: a. Settling theory; b. Use of gravity; c. Need to create an appropriate medium; d. Use of centrifugal force; e. Use of X-ray fluorescence; f. Use of hydrophobics; g. Use of magnetics; h. Density of particles; i. Effect of particle size and shape; j. Use of screening.


Provider Accreditation Requirements for the Subject:Physical Requirements:- Proven access to suitable learning facilities, tools and equipment to professionally deliver the learning as specified in the curriculum. Proven access to all the simulations, controlled work environments and demonstrations as set out in the given statements for the practical skills in the curriculum

Human Resources Requirements:- Facilitators of learning must be in possession of a national qualification in mineral processing practices at least at NQF 4 or industry recognised certificate with two years post qualification experience as a process controller or at least 5 years practical experience in a recognised mineral processing plant as a process controller and/or foreman- Facilitators of learning must be in possession of a OD ETDP certificate at NQF level 4 or recognised equivalent

Legal Requirements:- Providers of learning must comply with all OHS requirements



SECTION 3B: PRACTICAL SKILL MODULE SPECIFICATIONS

List of Practical Skills Modules for which Specifications are included:

Number Title NQF Level Credits313912-004-PM-01 Monitor and control the milling and separation processes 4 4313912-004-PM-02 Monitor and control the gravity processes 4 2313912-004-PM-03 Monitor and control the thickening processes 4 3313912-004-PM-04 Monitor and control the filtration processes 4 4313912-004-PM-05 Monitor and control the leaching processes 4 4313912-004-PM-06 Monitor and control the froth flotation processes 4 6313912-004-PM-07 Monitor and control the adsorption processes 4 5313912-004-PM-08 Monitor and control the elution processes 4 5313912-004-PM-09 Physically monitor the make-up, storage and distribution of

reagents/medium/catalists4 4

Total Practical Skill Credits: 37



313912-004-PM-01-Monitor and control the milling and separation processes (NQF Level: 4)

Purpose of the Module:

List of Practical Skills Included in this Module:

Number Title Credits

313912-004-PM-01-PS01 Physically start the milling section and monitor the flow of raw material from storage facility to the milling section

2

313912-004-PM-01-PS02 Stop, start and monitor the operation of the milling section using a computerised monitoring and control system

2

313912-002-PM-07-PS01: Physically start the milling section and monitor the flow of raw material from storage facility to the milling section (Credits: 4)

Scope of Practical Skill:

Given:Given a simulated or controlled work environment with all the equipment required for milling operations, a set volume of material to be milled, all consumables and the relevant milling media.

Be Able to:1. Physically inspect all the storage facilities, feeding/transport systems and the equipment and report any defects;2. Physically inspect the operational readiness of all the auxiliary equipment required for milling;3. Check that there is sufficient reagents available for the milling process4. Manually start all the equipment in the correct sequence5. Observe and monitor the flow of material from the storage facilities to the milling equipment6. Take readings from the relevant instrumentation, record and interpret what action is required7. Complete the required log sheets8. Communicate effectively to all up and down stream stakeholders.

Applied Knowledge

1. Equipment inspection processes and techniques2. Effective communication techniques3. Processes and techniques for identifying and dealing with problems in the milling section

Internal Assessment:1. Observe and evaluate the extent to which learners follow the standard operating procedures for startup, stop and monitoring of the process2. Evaluate the accuracy, completeness and relevance of information recorded on the log sheets3. Evaluate the timeliness, quality and accuracy of the communication4. Evaluate the extent to which learners correctly identify the causes of problems and initiate the appropriate corrective actions.



313912-004-PM-01-PS02 Stop, start and monitor the operation of the milling section using a computerised monitoring and control system (Credits: 4)


Given:Given a fully operational control room with a computerised control system and an operating milling section

Be Able to:1. Check the levels of raw materials in the storage facilities on the system and confirm the levels with the outside operator.2. On an ongoing basis identify problems, identify the causes and take appropriate corrective actions3. Check the availability and readiness of all equipment and machinery on the system and confirm the status with the outside operator.4. Check grinding media levels in the mill and take appropriate actions to correct if needed5. Access the computerised control system and read and interpret the status of the milling section on the system6. In sequence start the milling operation from the control room7. Stop, start and monitor the operation of the auxiliary systems associated with milling8. Stop the mill for maintenance and emergency situations9. Set the milling parameters according to production requirements and milling efficiency10. Complete the control room activity log sheet and shift reports11. Extract data from the system relating to operational efficiencies and record the information on the log sheets12. Respond to alarms13. On the computer system monitor the flow of material and take action to deal with problems and deviations14. Communicate with all stakeholders that the milling process will be started15. Communicate with the relevant stakeholders to supply raw material if required16. Monitor cyclone over and under flow

Applied Knowledge1. Techniques for operating a computerised control system2. Communication techniques3. Problem identification and solving techniques

Internal Assessment:



Provider Accreditation Requirements:Physical Requirements:- Proven access to suitable learning facilities, tools and equipment to professionally deliver the learning as specified in the curriculum. Proven access to all the simulations, controlled work environments and demonstrations as set out in the given statements for the practical skills in the curriculum



313912-004-PM-02-Monitor and control the gravity processes (NQF Level: 4)




313912-004-PM-02-PS01 Physically inspect the all gravity separation equipment, identify defects and take corrective actions

2

313912-002-PM-08-PS01: Physically inspect the all gravity separation equipment, identify defects and take corrective actions (Credits: 4)


Given:Given a simulated or controlled work environment with a range of gravity separation equipment and sufficient material to be separated

Be Able to:1. Physically inspect all equipment prior to start up and complete a pre-use checklist and report defects2. Make adjustment to the settings of the equipment in order to meet specific production requirements3. Physically start up the separation process in sequence4. Physically monitor the throughput and deal with any deviations5. Identify and clean spillages and remove/re-cycle the spillages in a secure manner6. Physically stop the equipment for emergency and maintenance purposes7. Prepare the work area for maintenance activities

Critical Activities to be Assessed Externally:



Applied Knowledge1. Gravity separation process2. Operating principles of all the gravity separation equipment3. Basic trouble shooting techniques







313912-004-PM-03-Monitor and control the thickening processes (NQF Level: 4)



Number Title Credits313912-004-PM-03-PS01 Physically start the thickening equipment and monitor and

control the feed into and through the thickeners2

313912-004-PM-03-PS02 Start the thickening equipment and monitor and control the feed into and through the thickeners from the control room

1

313912-004-PM-03-PS01: Physically start the thickening equipment and monitor and control the feed into and through the thickeners (Credits: 3)


Given:Given a simulated or controlled work environment with a full range of thickening and feeding equipment.

Be Able to:1. Make adjustment to the settings of the equipment in order to meet specific production requirements2. Physically monitor the throughput and deal with any deviations3. Physically inspect all equipment prior to start up and complete a pre-use checklist and report defects4. Physically start up the thickening process in sequence


Applied Knowledge




313912-004-PM-03-PS01: Start the thickening equipment and monitor and control the feed into and through the thickeners from the control room (Credits: 3)

Scope of Practical Skill:Given:Given a fully operational control room with a computerised control system and an operating thickening sectionBe Able to:1. Check the levels of raw materials in the storage facilities on the system and confirm the levels with the outside operator.2. On an ongoing basis identify problems, identify the causes and take appropriate corrective actions3. Check the availability and readiness of all equipment and machinery on the system and confirm the status with the outside operator.4. Access the computerised control system and read and interpret the status of the section on the system6. In sequence start the operation from the control room7. Stop, start and monitor the operation of the auxiliary systems associated with the section8. Stop the section for maintenance and emergency situations9. Set the operating parameters according to production requirements and efficiency standards10. Complete the control room activity log sheet and shift reports11. Extract data from the system relating to operational efficiencies and record the information on the log sheets12. Respond to alarms13. On the computer system monitor the flow of material and take action to deal with problems and deviations14. Communicate with all stakeholders that the process will be started15. Communicate with the relevant stakeholders to supply raw material if required16. Monitor cyclone over and under flow






313912-004-PM-04-Monitor and control the filtration processes (NQF Level: 4)



Number Title Credits313912-002-PM-10-PS01 Physically control the filtration process (feed rates and density of

material/pulp) through the filtration process2

313912-002-PM-10-PS02 Control the filtration process (feed rates and density of material/pulp) through the filtration process from a control room

2

313912-004-PM-04-PS01: Physically control the filtration process (feed rates and density of material/pulp) through the filtration process (Credits: 4)


Given:Given a simulated or controlled work environment with a full range of process equipment.

Be Able to:1. Physically prepare the filter for the filtering process2. Physically operate all the equipment in the section3. Physically monitor the sequences of the filtering process4. Physically monitor, control and dispatch the filtration product5. Communicate and report with the up and down stream processes and the control room

Applied Knowledge


313912-004-PM-04-PS02 Control the filtration process (feed rates and density of material/pulp) through the filtration process from a control room (Credits: 4)

Scope of Practical Skill:Given:Given a fully operational control room with a computerised control system and an operating section

Be Able to:1. Check the levels of raw materials in the storage facilities on the system and confirm the levels with the outside operator.2. On an ongoing basis identify problems, identify the causes and take appropriate corrective actions3. Check the availability and readiness of all equipment and machinery on the system and confirm the status with the outside operator.4. Check grinding media levels in the mill and take appropriate actions to correct if needed5. Access the computerised control system and read and interpret the status of the section on the system



6. In sequence start the operation from the control room7. Stop, start and monitor the operation of the auxiliary systems associated with the section8. Stop the section for maintenance and emergency situations9. Set the equipment parameters according to production requirements and efficiency standards10. Complete the control room activity log sheet and shift reports11. Extract data from the system relating to operational efficiencies and record the information on the log sheets12. Respond to alarms13. On the computer system monitor the flow of material and take action to deal with problems and deviations14. Communicate with all stakeholders that the process will be started15. Communicate with the relevant stakeholders to supply raw material if required16. Monitor cyclone over and under flow

Applied Knowledge



313912-004-PM-05-Monitor and control the leaching processes (NQF Level: 4)




313912-004-PM-05-PS01 Physically monitor the leaching process 2313912-004-PM-05-PS02 Monitor the leaching process from the control room 2



313912-004-PM-05-PS01: Physically monitor the leaching process (Credits: 4)


Given:

Be Able to:1. Physically determine the density of the leach feed;2. Physically monitor the tank levels in the leaching process;3. Physically operate all the equipment in the section;4. Physically monitor the reagent addition5. Monitor and control the leaching residence time;


Applied Knowledge


313912-004-PM-05-PS02: Monitor the leaching process from the control room (Credits: 4)

Scope of Practical Skill:Given:Given a fully operational control room with a computerised control system and an operating leaching section

Be Able to:1. Check the levels of raw materials in the storage facilities on the system and confirm the levels with the outside operator.2. On an ongoing basis identify problems, identify the causes and take appropriate corrective actions3. Check the availability and readiness of all equipment and machinery on the system and confirm the status with the outside operator.4. Check grinding media levels in the mill and take appropriate actions to correct if needed5. Access the computerised control system and read and interpret the status of the section on the system6. In sequence start the milling operation from the control room7. Stop, start and monitor the operation of the auxiliary systems associated with the operation8. Stop the mill for maintenance and emergency situations (Lock outs and permits)9. Set the milling parameters according to production requirements and efficiency standards10. Complete the control room activity log sheet and shift reports11. Extract data from the system relating to operational efficiencies and record the information on the log sheets12. Respond to alarms13. On the computer system monitor the flow of material and take action to deal with problems and deviations



14. Communicate with all stakeholders that the milling process will be started15. Communicate with the relevant stakeholders to supply raw material if required16. Monitor cyclone over and under flow

313912-004-PM-06 Monitor and control the agitation process (Credits: 5)

313912-005-PM-06-PS01: Physically monitor the agitation process (Credits: 3)


Given:

Be Able to:1. Check tank levels2. Check the air supply and initiate corrective action when required3. Inspect and operate all the equipment in the section4. Communicate and report with up and down stream processes and the control room

313912-004-PM-06-PS02: Monitor and control the agitation process from a control room (Credits 2)

Scope of Practical Skill:Given:Given a fully operational control room with a computerised control system and an operating agitation section

Be Able to:1. Check the levels of raw materials in the storage facilities on the system and confirm the levels with the outside operator.2. On an ongoing basis identify problems, identify the causes and take appropriate corrective actions3. Check the availability and readiness of all equipment and machinery on the system and confirm the status with the outside operator.4. Check grinding media levels in the mill and take appropriate actions to correct if needed5. Access the computerised control system and read and interpret the status of the section on the system6. In sequence start the milling operation from the control room7. Stop, start and monitor the operation of the auxiliary systems associated with the operation8. Stop the mill for maintenance and emergency situations9. Set the milling parameters according to production requirements and efficiency standards10. Complete the control room activity log sheet and shift reports11. Extract data from the system relating to operational efficiencies and record the information on the log sheets12. Respond to alarms13. On the computer system monitor the flow of material and take action to deal with problems and deviations14. Communicate with all stakeholders that the milling process will be started15. Communicate with the relevant stakeholders to supply raw material if required16. Monitor cyclone over and under flow



313912-004-PM-06-Monitor and control the froth flotation processes (NQF Level: 4)




313912-004-PM-06-PS01 Physically monitor and control the froth flotation process 3313912-004-PM-06-PS02 Monitor and control the feed rate and density from the control

room3

313912-004-PM-06-PS01: Physically monitor and control the froth flotation process (Credits: 3)


Given:

Be Able to:Physically monitor and control the feed rate and densityPhysically monitor and control the addition of applicable reagents into the processPhysically inspect and operate all the equipment in the section

Communicate

Physically stop and prepare the flotation process for maintenance and during emergencies

313912-004-PM-06-PS02 Monitor and control the feed rate and density from the control room (Credits: 3)

Scope of Practical Skill:Given:Given a fully operational control room with a computerised control system and an operating section

Be Able to:1. Check the levels of raw materials in the storage facilities on the system and confirm the levels with the outside operator.2. On an ongoing basis identify problems, identify the causes and take appropriate corrective actions3. Check the availability and readiness of all equipment and machinery on the system and confirm the status with the outside operator.



4. Check grinding media levels in the mill and take appropriate actions to correct if needed5. Access the computerised control system and read and interpret the status of the section on the system6. In sequence start the milling operation from the control room7. Stop, start and monitor the operation of the auxiliary systems associated with the operation8. Stop the mill for maintenance and emergency situations9. Set the milling parameters according to production requirements and efficiency standards10. Complete the control room activity log sheet and shift reports11. Extract data from the system relating to operational efficiencies and record the information on the log sheets12. Respond to alarms13. On the computer system monitor the flow of material and take action to deal with problems and deviations14. Communicate with all stakeholders that the milling process will be started15. Communicate with the relevant stakeholders to supply raw material if required16. Monitor cyclone over and under flow

313912-004-PM-07-Monitoring and controlling the adsorption processes (NQF Level: 4)



Number Title Credits313912-004-PM-07-PS01 Physically monitor the pulp feed rate and density through the

adsorption process3

313912-004-PM-07-PS02 Monitor and control the pulp feed rate and density into the adsorption process

2

313912-004-PM-07-PS01: Physically monitor the pulp feed rate and density through the adsorption process (Credits: 3)


Given:

Be Able to:Physically monitor and control the carbon concentration in the adsorption processPhysically monitor and control the counter current transfer of carbon in the adsorption processInspect and operate all equipment in the section

Physically transfer loaded carbon to the elution processCommunicate

Monitor and control the addition of fresh carbon into the adsorption system



313912-004-PM-08-Monitor and control the elution processes (NQF Level: 2)



Number Title Credits313912-004-PM-08-PS01 Physically monitor and control the transfer of loaded carbon from

the adsorption to and through the elusion process3

313912-004-PM-08-PS02 Monitor and control the transfer of loaded carbon from the adsorption to the elusion column from a control room

2

313912-004-PM-08-PS01: Physically monitor and control the transfer of loaded carbon from the adsorption to and through the elusion process (Credits: 3)


Given:

Be Able to:Monitor and control the addition of reagents through the elusion column.Physically monitor and control the sequence of events in the elution processInspect and operate all equipment in the section

Communicate


Applied Knowledge




313912-004-PM-08-PS02 Monitor and control the transfer of loaded carbon from the adsorption to the elution column from a control room (Credits: 2)


Given:

Be Able to:1. Check the levels of raw materials in the storage facilities on the system and confirm the levels with the outside operator.2. On an ongoing basis identify problems, identify the causes and take appropriate corrective actions3. Check the availability and readiness of all equipment and machinery on the system and confirm the status with the outside operator.4. Check grinding media levels in the mill and take appropriate actions to correct if needed5. Access the computerised control system and read and interpret the status of the section on the system6. In sequence start the milling operation from the control room7. Stop, start and monitor the operation of the auxiliary systems associated with the operation8. Stop the mill for maintenance and emergency situations9. Set the milling parameters according to production requirements and efficiency standards10. Complete the control room activity log sheet and shift reports11. Extract data from the system relating to operational efficiencies and record the information on the log sheets12. Respond to alarms13. On the computer system monitor the flow of material and take action to deal with problems and deviations14. Communicate with all stakeholders that the milling process will be started15. Communicate with the relevant stakeholders to supply raw material if required16. Monitor cyclone over and under flow


Applied Knowledge


:



313912-004-PM-08-PS03 Monitor and control the elution process from a control room (Credits: )

Scope of Practical Skill:Given:Given a fully operational control room with a computerised control system and an operating elution section

Be Able to:1. Check the levels of raw materials in the storage facilities on the system and confirm the levels with the outside operator.2. On an ongoing basis identify problems, identify the causes and take appropriate corrective actions3. Check the availability and readiness of all equipment and machinery on the system and confirm the status with the outside operator.4. Check grinding media levels in the mill and take appropriate actions to correct if needed5. Access the computerised control system and read and interpret the status of the section on the system6. In sequence start the operation from the control room7. Stop, start and monitor the operation of the auxiliary systems associated with the operation8. Stop the mill for maintenance and emergency situations9. Set the milling parameters according to production requirements and efficiency standards10. Complete the control room activity log sheet and shift reports11. Extract data from the system relating to operational efficiencies and record the information on the log sheets12. Respond to alarms13. On the computer system monitor the flow of material and take action to deal with problems and deviations14. Communicate with all stakeholders that the milling process will be started15. Communicate with the relevant stakeholders to supply raw material if required16. Monitor cyclone over and under flow



313912-004-PM-09-Physically monitor the make-up, storage and distribution of reagents (NQF Level: 8)



Number Title Credits313912-004-PM-09-PS01 Identify and safely handle a range of reagents 4

313912-004-PM-09-PS01: Identify and safely handle a range of reagents (Credits: 4)


Given:Given a simulated or controlled work environment with a range of reagents, storing facilities and all equipment.

Be Able to:1. Receive, record and store the reagents2. Identify the reagents and interpret the material safety data sheet for the specific reagent3. Oversee the offloading of reagents from different types of road or rail transportation4. Complete and capture all the required documentation5. Use a given recipe to make up a range of reagents


Applied Knowledge1. Use of MSDS (Material safety data sheets)

Internal Assessment:1. Observe and evaluate the extent to which learners follow the appropriate procedures for receiving, handling and storing reagents2. Evaluate the completeness and accuracy of all the required documentation



SECTION 3C: WORK EXPERIENCE MODULE SPECIFICATIONS

List of Work Experience Module Specifications

Number Title NQF Level Credits313912-004-WM-01 Exposure to the full extractive metallurgical mineral processes 4 60

Total Work Experience Credits: 60



313912-001-WM-01- Exposure to the full extractive metallurgical mineral processes

Purpose of the Module

List of Experiences included in this module


313912-002-WM-03-01 Conduct all the physical work required in the plant for a period of sixteen shifts

32

313912-002-WM-03-02 Operate all plant sections and achieve all the required efficiency and production targets over a period of six months

48

313912-004-WM-01-01: Conduct all the physical work required in the section for a period of six months

Guidelines for Work Experience1. Participate in shift hand over processes in the workplace and complete all required hand over documentation;2. Inspect and operate (stop, start, monitor and control) all the equipment in all the sections on the plant, complete all

checklists and report as per site specific requirements;3. Deal with emergency situations, take appropriate action and communicate effectively;4. Prepare the equipment for planned maintenance;5. Report defects and initiate corrective action as per the site specific requirements;6. Execute minor first line maintenance as specified in site specific requirements;7. Execute all required housekeeping duties as required on the plant;8. Comply with all site specific health and safety requirements;9. Comply with all site specific operating procedures, rules and codes of practice;10. Identify changes in working conditions and initiate the appropriate actions as per site specific requirements;

Contextual Workplace Knowledge1. Site specific codes of practice, operating procedures standards and rules;2. Site specific hazards and risks associated with all the sections and the related equipment of the plant;3. Site specific vision, mission and production objectives;4. Site specific operating parameters for all the equipment in all the sections on the plant;5. Plant flow and the use of the product by the up and down stream processes;6. Site specific quality and quantity requirements for each stage of the production process;7. Site specific security requirements;8. Site specific management communication and reporting processes9. Site specific techniques for operating the equipment and processes for each of the sections

Supporting Evidence

1. Shift reports2. Learner generated observation report3. Completed planned task observations and risk assessments4. Production reports and trends5. Supervisor generated performance reports



313912-004-WM-01-02: Operate the plant from a control room for a period of six months Guidelines for Work Experience

1. Participate in shift hand over processes in the workplace and complete all required hand over documentation;2. Review all shift reports and initiate appropriate action at the start of the shift;3. Complete shift handover activities and control (stop, start, monitor and control) all the equipment in all the sections on

the plant, complete all checklists and report as per site specific requirements;4. Deal with emergency situations, take appropriate action and communicate effectively;5. Operate equipment for maintenance purposes as required by maintenance staff;6. Oversee the preparation of the equipment for planned maintenance;7. Report defects and deviations and initiate corrective action as per the site specific requirements;8. Execute all required housekeeping duties as required;9. Comply with all site specific health and safety requirements;10. Comply with all site specific operating procedures, rules and codes of practice;11. Identify changes in working conditions and initiate the appropriate actions as per site specific requirements;12. Prepare reports and execute all required calculations as per site requirements;

Contextual Workplace Knowledge1. Site specific codes of practice, operating procedures standards and rules;2. Site specific hazards and risks associated with all the sections and the related equipment of the plant;3. Site specific vision, mission and production objectives;4. Site specific operating parameters for all the equipment in all the sections on the plant;5. Plant flow and the use of the product by the up and down stream processes;6. Site specific quality and quantity requirements for each stage of the production process;7. Site specific security requirements;8. Site specific management communication and reporting processes

Supporting Evidence1. Shift reports2. Learner generated observation report3. Completed planned task observations and risk assessments4. Production reports and trends (Computerised control system reports)5. Supervisor generated performance reports6. Clearance certificates and permits as per site specific requirements

Process Controller- Extractive Metallurgybenvanas.co.za/downloads/MQA/pages/CONTROLLERS/V03... · Web viewMineral Beneficiation Process Controller: (Extractive Metallurgy) Table of

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