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Process Controller- Extractive Metallurgy

Curriculum DocumentCurriculum Code Curriculum Title

313912-003 Mineral Beneficiation Process Controller: (Extraction Metallurgy)

DRAFT CURRICULUM – JUNE 2014


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: Ensuring compliance with all Occupational Health, Safety and Environmental requirements to minimise the operational risk in the plant. (NQF Level: 4)........................5

TASK 02: Monitoring and controlling the availability and preparation of raw materials to achieve production targets for a designated production period. (NQF Level: 3).........5

TASK 03: Monitoring and controlling the extractive metallurgical processes..........................................................6

(NQF Level: 4)..........................................................................................................................................................6

TASK 04: Monitoring and controlling the waste handling processes in an extractive metallurgical plant. (NQF Level: 3)....................................................................................................................................................................6

SECTION 3: CURRICULUM COMPONENT SPECIFICATIONS SECTION...................................................................7

3A: KNOWLEDGE SUBJECT SPECIFICATIONS.......................................................................................................7

313912-001-KS-01: Occupational Health and Safety..........................................................................................7

313912-002-KS-02: Extraction Metallurgy...............................................................................................................9

SECTION 3B: PRACTICAL SKILL MODULE SPECIFICATIONS.............................................................................17

313912-001-PM-01-Monitor the Occupational Health, Safety and environmental compliance in the beneficiation processes (NQF Level: 4).........18

313912-001-PM-02-Monitor and verify the availability of raw materials (NQF Level: 3)........................................21

313912-001-PM-03-Facilitate the smooth flow of raw material by means of the material handling and transportation systems and equipment (NQF Level: 3)..........................................................................................24

313912-001-PM-04-Check and report the quality/parameters of the available raw material (NQF Level: 3)........27

313912-001-PM-05-Determine the raw material requirements to achieve the production targets (NQF Level: 4)29

313912-001-PM-06-Start, monitor, control and stop all size reduction equipment (NQF Level: 4).......................31

313912-002-PM-07-Monitor and control the milling and cycloning processes (NQF Level: 4)..............................33

313912-002-PM-08-Monitor and control the gravity processes (NQF Level: 4)....................................................36



313912-002-PM-09-Monitor and control the thickening processes (NQF Level: 4)...............................................38

313912-002-PM-10-Monitor and control the leaching processes (NQF Level: 4)..................................................41

313912-002-PM-11-Monitor and control the froth flotation processes (NQF Level: 4)..........................................44

313912-002-PM-12-Monitoring and controlling the adsorption processes (NQF Level: 4)....................................45

313912-002-PM-13-Monitor and control the elution processes (NQF Level: 4)....................................................47

313912-002-PM-14-Monitor and control the electro winning/precipitation processes (NQF Level: ).....................51

313912-002-PM-16-Physically monitor the make-up, storage and distribution of reagents (NQF Level: )............56

313912-002-PM-17-Monitor and control the regeneration process (NQF Level: ).................................................57

313912-002-PM-18-Monitor and control the preparation of tailings for re-use (NQF Level: )................................60

313912-002-PM-19-Monitor and control the disposal/transfer of tailings (NQF Level: )........................................62

313912-002-PM-20-Monitor and control the disposal of waste material (Bags, buckets, wood chips etc) (NQF Level: )...................................................................................................................................................................63

SECTION 3C: WORK EXPERIENCE MODULE SPECIFICATIONS........................................................................65

313912-002-WM-01 - Exposed to risk management processes for all areas of the plant.....................................66

313912-002-WM-02 - Exposure to the full range of raw material preparation processes and equipment used on the specific site.......................................................................................................................................................70

313912-002-WM-03 - Exposure to the milling and cycloning processes...............................................................71

313912-002-WM-04 - Exposure to the thickening processes................................................................................72

313912-002-WM-05 - Exposure to the filtration processes....................................................................................73

313912-002-WM-06 - Exposure to the leaching processes...................................................................................74

313912-002-WM-07 - Exposure to the full range of waste handling and disposal processes used on the specific site..........................................................................................................................................................................75


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


SECTION 1: CURRICULUM OVERVIEW

Occupational Information

Associated Occupations

Occupation or Specialisation Addressed by this Curriculum

Alternative Titles used by Industry



Curriculum Information

Relation of this Curriculum to the Occupation and QualificationProgression

Notes Regarding the Progression:



Curriculum Structure

Knowledge Subjects

Number Title NQF Level Credits

313912-003-KS-01 Occupational Health and Safety 3 5

313912-003-KS-02 Extraction Metallurgy 4 29

313912-003-KS-03 Process Plant Management 4 12

Total Knowledge Credits: 47

Practical Skills Modules


313912-002-PM-01 Monitor the Occupational Health, Safety and environmental compliance in the beneficiation processes

0

313912-002-PM-02 Monitoring and controlling the communition (Size reduction) processes.

0

313912-002-PM-03 Monitoring and controlling the production parameters (Feed rates, milling rates etc.)

0

313912-002-PM-04 Monitoring and controlling the raw material blending and mixing processes

0

313912-002-PM-05 Stop start and control the operation of all auxiliary equipment 0313912-002-PM-06 Monitor and control the milling and cycloning processes 8313912-002-PM-07 Monitor and control the gravity processes 4313912-002-PM-08 Monitor and control the thickening processes 0313912-002-PM-09 Monitor and control the filtration processes 8313912-002-PM-10 Monitor and control the leaching processes 8313912-002-PM-11 Monitor and control the froth flotation processes 12313912-002-PM-12 Monitoring and controlling the adsorption processes 10313912-002-PM-13 Monitor and control the elution processes 10313912-002-PM-14 Monitor and control the electro winning/precipitation processes 4313912-002-PM-15 Physically take and analyse samples for extraction metallurgical

processes0

313912-002-PM-16 Physically monitor the make-up, storage and distribution of reagents

8

313912-002-PM-17 Monitor and control the regeneration process 8313912-002-PM-18 Monitor and control the preparation of tailings for re-use 0313912-002-PM-19 Monitor and control the disposal/transfer of tailings 0313912-002-PM-20 Monitor and control the disposal of waste material (Bags,

buckets, wood chips etc)0

Total Practical Skill Credits: 80



Work Experience Modules


313912-002-WM-01 Exposed to risk management processes for all areas of the plant 0313912-002-WM-02 Exposure to the full range of raw material preparation processes

and equipment used on the specific site.0

313912-002-WM-03 Exposure to the milling and cycloning processes 0313912-002-WM-04 Exposure to the thickening processes 0313912-002-WM-05 Exposure to the filtration processes 0313912-002-WM-06 Exposure to the leaching processes 0313912-002-WM-07 Exposure to the full range of waste handling and disposal

processes used on the specific site.0

Total Work Experience Credits: 0

TOTAL QUALIFICATION CREDITS:Knowledge Percentage: 28% Practical Skills Percentage: 72% Workplace Percentage: 0%

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: Ensuring compliance with all Occupational Health, Safety and Environmental requirements to minimise the operational risk in the plant. (NQF Level: 4)TASK 02: Monitoring and controlling the availability and preparation of raw materials to achieve production targets for a designated production period. (NQF Level: 3)TASK 03: Monitoring and controlling the extractive metallurgical processes(NQF Level: 4)

TASK 04: Monitoring and controlling the waste handling processes in a extractive metallurgical plant.(NQF Level: 3)

Task DetailsTASK 01: Ensuring compliance with all Occupational Health, Safety and Environmental requirements to minimise the operational risk in the plant. (NQF Level: 4)

Unique Product or Service All risks eliminated or managed during the production process

Occupational Responsibilities Monitor the Occupational Health, Safety and environmental compliance in the beneficiation processes

Context Exposed to risk management processes for all areas of the plant

TASK 02: Monitoring and controlling the availability and preparation of raw materials to achieve production targets for a designated production period. (NQF Level: 3)

Unique Product or Service Raw materials prepared (Crushing, screening and milling)

Occupational Responsibilities Monitoring and controlling the communition (Size reduction) processes. Monitoring and controlling the production parameters (Feed rates, milling rates etc)

Monitoring and controlling the raw material blending and mixing processes Stop start and control the operation of all auxiliary equipment

Context Exposure to the full range of raw material preparation processes and equipment used on the specific

site.



TASK 03: Monitoring and controlling the extractive metallurgical processes(NQF Level: 4)

Unique Product or Service Raw materials processed

Occupational Responsibilities Monitor and control the milling and cycloning processes Monitor and control the gravity processes Monitor and control the thickening processes Monitor and control the filtration processes Monitor and control the leaching processes Monitor and control the froth flotation

processes Monitoring and controlling the adsorption processes Monitor and control the elution processes Monitor and control the electro winning/precipitation processes Physically take and analyse samples for extraction metallurgical processes Physically monitor the makeup, storage and distribution of reagents Monitor and control the regeneration process

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

processes Exposure to the filtration

processes Exposure to the leaching

processes

TASK 04: Monitoring and controlling the waste handling processes in an extractive metallurgical plant. (NQF Level: 3)

Unique Product or Service Waste disposed

Occupational Responsibilities Monitor and control the preparation of tailings for re-use Monitor and control the disposal/transfer of tailings Monitor and control the disposal of waste material (Bags, buckets, wood chips etc)

Context Exposure to the full range of waste handling and disposal processes used on the specific site.



SECTION 3: CURRICULUM COMPONENT SPECIFICATIONS SECTION

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


313912-003-KS-01 Occupational Health and Safety 3 5

313912-003-KS-02 Extraction Metallurgy 4 29

313912-003-KS-03 Process Plant Management 4 2

Total Knowledge Credits: 31

313912-001-KS-01: Occupational Health and Safety

Purpose of the Knowledge SubjectThe focus of the learning in this subject is on developing learner’s knowledge and understanding of the key concepts, principles and theories that underpins the Occupational Health and safety requirements associated with the job of a process controller.

Topics included in this subject:

TOTAL TOPIC CREDITS: 5

313912-001-KS-01:01 -Concepts and application principles of all occupational health, safety and environmental requirements related to the beneficiation process. (Intermediate) (Credits: 5)

Topic Elements to be covered include:1. Identify all relevant legislation applicable to mineral beneficiation;2. Identify which inspections are required and describe the purpose and process of each of them: a. Inspections of PPE; b. Inspections of Machines including guarding, tools and equipment; c. Inspection of the environment; d. dealing with changing situations;3. Explain the purpose and application of incident and accident investigations: a. what needs to be investigated; b. How to conduct the investigations; c. who must be involved in the investigations; d. Reporting processes (internal and external); e. Processes for implementing corrective actions;4. Explain what is meant by an environmental management system: a. who the stakeholders are; b. Roles and responsibilities of the stakeholders; c. Structure of the reporting systems; d. Processes for follow up and review; e. Processes to implement corrective actions;5. Give an overview of the applicable international and national standard systems and requirements;6. Explain what is meant by emergency preparedness and response: a. Identify emergencies; b. immediate actions to be taken; c. Evacuation procedures; d. Requirements for reporting;7. Explain the consequences of non-compliance to the regulatory requirements;8. Explain the purpose of the relevant legislation;9. Describe the roles and responsibilities of employers and employees regarding safety, health and environmental practices in the workplace;

TOPIC NUMBER TOPIC TITLE WEIGHT CREDITS

313912-001-KS-01:01 Concepts and application principles of all occupational health, safety and environmental requirements related to the beneficiation process. (Intermediate)

5



10. Describe the process of Hazard identification, risk assessment and control: a. what risk management is; b. Key terms used in risk management (Hazard, risk, consequence, probability etc.); c. Roles and responsibilities; d. The various processes;11. Describe what is meant by behavioral safety and give examples of how this is applied in the workplace;12. Explain what is meant by an occupational health and safety management system: a. who the stakeholders are; b. Roles and responsibilities of the stakeholders; c. Structure of the reporting systems; d. Processes for follow up and review; e. Processes to implement corrective actions;13. Describe the process for doing task observations and indicate how the information out of these observations will be used.

Internal Assessment Criteria:

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

313912-002-KS-02: Extraction Metallurgy



Purpose of the Knowledge Subject


TOPIC NUMBER TOPIC TITLE WEIGHT CREDITS313912-002-KS-02:01 Concepts and principles of mineralogy (Intermediate) 4313912-002-KS-02:02 Tailing disposal processes (Basic) 3313912-002-KS-02:04 Scientific concepts and calculations related to extraction

metallurgical processes (Basic) (Flows, pressures, SG, temperature, ph )

12

313912-002-KS-02:05 Concepts and principles of the mechanical operations of equipment used in a metallurgical process (Basic)

6

313912-002-KS-02:06 Principles of the various chemical processes and interactions that take place in an extraction metallurgical process (Intermediate)

4

313912-002-KS-02:07 Metallurgical principles of mineral extraction using different techniques (Intermediate)

313912-002-KS-02:08 Principles and concepts of systems thinking and cause and effect analysis (Basic)

313912-002-KS-02:09 Concepts and principles of conducting trouble shooting on equipment and machines and corrective actions required to optimise production (Intermediate)


313912-002-KS-02:01 -Concepts and principles of mineralogy(Intermediate) (Credits: 4)

Topic Elements to be covered include:1. Explain the main features and physical properties of the various minerals mined in SouthAfrica 2. Identify the various minerals in terms of their physical characteristics3. Describe the potential hazards associated with the processing of the different minerals4. Give examples of how the various physical properties of minerals impact on the beneficiation/extraction processes



5. Identify and describe the environmental impact of beneficiating the various minerals in terms of the chemical composition of the minerals


313912-002-KS-02:02 -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.


313912-002-KS-02:04 -Scientific concepts and calculations related to extraction metallurgical processes (Basic) (Flows, pressures, SG, temperature, ph ) (Credits: 12)

Topic Elements to be covered include:1. Define what a metallurgist does and how metallurgy is applied for mineral beneficiation: a.Definition of metallurgy; b. Different types of metallurgy; 2. Describe the extraction metallurgical process;3. Define and explain the key terms used in extraction metallurgy a. Flow, flow rate and the implications of flow on the process; b. Density; c. Acidity and alkalinity; d. Viscosity; e. Chemical separation; f. Mechanical separation; g. Impact of temperature; h. Impact of pressure; i. Oxidation and reduction;4. Apply the various mathematical and scientific formulas for calculating the key values used in the extraction metallurgical process; a. Volume; b. Concentration; c. ratios; d. flow rates;e. Percentages; f. Basic chemical reaction formulas; g. Viscosity; h. Acidity and alkalinity; i. Mass5. Explain the principle of thermodynamics as applied in extraction metallurgy6. Explain the law of conservation of energy 7. Describe the principles of corrosion in a process plant and the actions required to minimise corrosion




313912-002-KS-02:05 -Concepts and principles of the mechanical operations of equipment used in a metallurgical process (Basic) (Credits: 6)

Topic Elements to be covered include:1. Identify the different types of energy sources used in a metallurgical plant and give examples of each;2. Identify and describe the different categories of equipment used in a metallurgical process and indicate purpose and use of each of them;3. Identify and describe the purpose of the main components of the various categories of equipment;4. Describe the distribution of the various energy sources in a metallurgical process;5. Explain how electricity works and give examples of how the various electrical phases are applied in the metallurgical process (DC, AC, voltage, implications of these);6. Give examples of the front line maintenance tasks required for the various categories of equipment (Lubrication, replacement parts, testing for wear, physical indicators of equipment failure);7. Identify and locate the key measuring equipment/indicators installed on the various categories of equipment and explain the purpose of each of them;8. Explain the processes for conducting basic trouble shooting on the engineering components of the plant.


313912-002-KS-02:06 -Principles of the various chemical processes and interactions that take place in an extraction metallurgical process (Intermediate) (Credits: 4)

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;


313912-002-KS-02:07 -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; g. Density of particles; h. Effect of particle size and shape; i. Use of screening.




313912-002-KS-02:08 -Principles and concepts of systems thinking and cause and effect analysis (Basic) (Credits: 2)

Topic Elements to be covered include: Topic Elements to be covered include:1. Explain what is meant by an operational system and how the interrelationship between various system components impact on final results;2. Explain the process for using the cause and effect principle to identify the root causes of problems;3. Describe the typical management process (PLOC);4. Explain how to make effective decisions when choosing between various alternative solutions (Needs analysis);5. Describe the process for action planning and protecting action plans (PREVENTATIVE AND CONTINGENCY ACTIONS).


313912-002-KS-02:09 -Concepts and principles of conducting trouble shooting on equipment and machines and corrective actions required to optimise production (Intermediate) (Credits: 3) Topic Elements to be covered include:1. Explain the steps that must be followed to conduct trouble shooting on machinery and equipment;2. Describe the principles for using checklists (Pre start, operational and shut down);3. Explain the use of permits when work is done on machinery and equipment: a. list total range of permits; b. when permits must be issued; c. authorisation of permits; d. Safety actions that must be done before permits are issued; e. Sign off and closure of permits; f. Filing and safe keeping of permits; 4. Identify the leading indicators of defects and potential defects on machinery and equipment;5. Explain the procedures for reporting defects.


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





313912-002-KS-02: Process Plant Management

Purpose of the Knowledge Subject


TOPIC NUMBER TOPIC TITLE WEIGHT CREDITS313912-002-KS-02:03 Concepts and operating principles of process logical control

systems (Basic)313912-002-KS-02:04 Purpose and application principles of all the materials

handling and transportation equipment (Basic)313912-002-KS-02:05 Principles for determining the quality specifications for final

products and the various methodologies associated with it (Intermediate)

313912-002-KS-02:06 Analyse and interpret trends and related statistical information and identify corrective action(Basic)

313912-002-KS-02:07 Factors that affect the efficiency of the process (Intermediate) 2313912-002-KS-02:08 Executing the basic calculations to determine the efficiency of

the mineral extraction process at the various stages of the process(Intermediate)

313912-002-KS-02:09 Principles of waste handling and the associated regulatory requirements (Intermediate)

313912-002-KS-02:10 Environmental impact of managing tailings and production waste (Basic)

313912-002-KS-02:11 Operating principles of production reporting and the generic structures and implications of production reports (Basic)


313912-002-KS-02:03 -Concepts and operating principles of process logical control systems (Basic) (Credits: 12)

Topic Elements to be covered include:1. Explain what is meant by Process Logic Controller and what the main purpose of a PLC(SCADA) is in a beneficiation plant;2. Identify and describe the advantages of using programmed logic controllers in a beneficiation plant;3. Explain the process of manual process control in the event of PLC failure;4. Explain the protocols that can be taken to bypass programmed process steps when required;5. Describe the process for manually operating the PLC from the remote control boxes in the sections on the plant;6. Explain the protocols for conducting fault finding in the beneficiation process using thePLC;7. Explain what the appropriate actions are relating to alarm conditions;8. Describe the basic risks associated with the use of PLC and indicate how a process controller will mitigate these risks: a. Bypassing the system without authorization; b. Sabotage; c. Misuse of the computer system; d. System failure; e. Loss of manual operating skills; f. Misleading instrument readings;9. Describe the main characteristics of a typical PLC (interlocks, stop and start, loops, lock out procedures, changing of set points).




313912-002-KS-02:04 -Purpose and application principles of all the materials handling and transportation equipment (Basic) (Credits: 8)

Topic Elements to be covered include: 1. Identify and describe the different types of material handling equipment a. Mobile liftingand transporting equipment; b. Conveying systems (stackers, reclaimers); c. Feeders and screens; d. Pumping systems; e. Storage systems ( silos, bins, hoppers etc.) f. Crushing and breaking systems; g. Washing system h. Classifying systems;2. List and describe the main components of each of the systems;3. Describe the key operating principles of each of the systems: a. Purpose, b. How it works, c. Energy source; d. Auxiliary systems and controls (includes instrumentation and safety systems) e. Inspections and maintenance;4. Explain what is meant by operating parameters and indicate how the parameters are determined: a. Capacity; b. throughput, c. Efficiency;5. Identify and describe the key factors that will influence the operating efficiency, throughput and capacity of the equipment.


313912-002-KS-02:05 -Principles for determining the quality specifications for final products and the various methodologies associated with it (Intermediate) (Credits: 3)

Topic Elements to be covered include:

1. Explain what is meant by quality, quality control and quality management systems;2. Explain what sampling is and how the results of sampling is used in the quality management process;3. Identify and describe the different methods of sampling (grab, belt cut, automatic sampling, stockpile sampling etc.);4. Explain the logic behind setting up a sampling programme; a. sampling points, b. Frequency of sampling, c. Sample size, d. Need for accuracy and precision;5. Explain the process of sampling (Taking samples, preparing samples, transportation of samples, types of analysis by laboratory, processing of sample results, re-sampling if required);6. Explain the consequences of incorrect sampling practices;7. Describe the use of on line analysers;8. Explain how methods and factors that will impact on the quality of the final product: a. Blending and mixing b. Machine setting; c. Operating parameters; d. Raw Material quality




313912-002-KS-02:06 -Analyse and interpret trends and related statistical information and identify corrective action (Basic) (Credits: 4)

Topic Elements to be covered include: 1. Explain what is meant by statistical analysis;2. Explain the meaning of key statistical terms: a. Ratios, b. Percentages; c. averages; d. mean; e. frequency; f. mode; g. trend;3. Interpret various forms of graphs a. Line; b. Bar charts; c. Pie charts; d, Scatter graphs;4. Use raw data to manually develop basic graphs;5. Use a spreadsheet computer based programme to input data and extract basic graphs;6. Identify statistical conformance and deviations from the expected norms and report them appropriately.


313912-002-KS-02:07 -Factors that affect the efficiency of the process (Intermediate) (Credits: 2)

Topic Elements to be covered include:1. Identify and give examples of the key factors that will impact on the efficiency of the metallurgical process (Condition and availability of equipment; environmental factors; quality and availability of the raw materials and consumables; particle size; availability and competence of labour, efficiency of the process)2. Explain the role of the process controller in dealing with the various impacting factors3. Identify and explain the various cost drivers that impacts on the feasibility of a metallurgical plant and indicate what can be done to manage these drivers. 4. Explain the revenue drivers of a production facility and give examples of how market factors impact on the profitability of the operation


313912-002-KS-02:08 -Executing the basic calculations to determine the efficiency of the mineral extraction process at the various stages of the process (Intermediate) (Credits: 1)

Topic Elements to be covered include:1. Using given data calculate screening efficiencies and circulating load, crushing ratios.2. Using given data calculate the area of the screen and determine the volume capacity of the screen.




313912-002-KS-02:09 -Principles of waste handling and the associated regulatory requirements (Intermediate) (Credits: 1)

Topic Elements to be covered include:

1. Explain the necessity of waste handling and pollution control in a beneficiation operation;2. Identify the different types of waste generated in a beneficiation process (including tailings and slurry);3. Explain the general principles of waste separation;4. Identify the different types of equipment required for effective waste handling;5. Describe the consequences of not adhering to effective waste management principles and regulatory requirements including codes of practices and guidelines;6. Describe the minimum criteria for the deposition of waste.


Provider Accreditation Requirements for the Subject:






SECTION 3B: PRACTICAL SKILL MODULE SPECIFICATIONS

List of Practical Skills Modules for which Specifications are included:


313912-002-PM-01 Monitor the Occupational Health, Safety and environmental compliance in the beneficiation processes

11

Monitor and verify the availability of raw materials 6

Facilitate the smooth flow of raw material by means of the material handling and transportation systems and equipment

18

Check and report the quality/parameters of the available raw material

6

Determine the raw material requirements to achieve the production targets

6

313912-002-PM-02 Monitoring and controlling the communition (Size reduction) processes.

6

313912-002-PM-03 Monitoring and controlling the production parameters (Feed rates, milling rates etc)

6

313912-002-PM-06 Monitor and control the milling and cycloning processes 8313912-002-PM-07 Monitor and control the gravity processes 4313912-002-PM-08 Monitor and control the thickening processes 6313912-002-PM-09 Monitor and control the filtration processes 8313912-002-PM-10 Monitor and control the leaching processes 8313912-002-PM-11 Monitor and control the froth flotation processes 12313912-002-PM-12 Monitoring and controlling the adsorption processes 10313912-002-PM-13 Monitor and control the elution processes 10313912-002-PM-14 Monitor and control the electro winning/precipitation processes 4313912-002-PM-16 Physically monitor the make-up, storage and distribution of

reagents8

313912-002-PM-17 Monitor and control the regeneration process 8313912-002-PM-18 Monitor and control the preparation of tailings for re-use 0313912-002-PM-19 Monitor and control the disposal/transfer of tailings 0313912-002-PM-20 Monitor and control the disposal of waste material (Bags,

buckets, wood chips etc)0

Total Practical Skill Credits: 80



313912-001-PM-01-Monitor the Occupational Health, Safety and environmental compliance in the beneficiation processes (NQF Level: 4)

Purpose of the Module:

List of Practical Skills Included in this Module:

Number Title Credits313912-001-PM-01-PS01 Conduct all start of shift procedures 3313912-001-PM-01-PS02 Identify health, safety and environmental hazards and risks in the

lump ore beneficiation environment (includes risk assessments)2

313912-001-PM-01-PS03 Ensure that all people entering the environment complies with relevant Safety health and Environmental standards and regulatory requirements.

3

313912-001-PM-01-PS04 Identify problems with the operational efficiency of all health and safety equipment and devices (Ongoing inspections)

3

313912-001-PM-01-PS01 Conduct all start of shift procedures(Credits: 3)

Scope of Practical Skill:

Given:Given a simulated or controlled work environment with a team of staff required to operate a lump ore beneficiation plant.

Be Able to:1. Conduct an inspection to check that all team members are fit for work and that all requiredPPE is available and in acceptable condition2. Conduct a health and safety discussion3. Deal with employees that are unfit for work4. Present and discuss the production results and explain the target for the day5. Communicate special instructions and management briefs6. Determine the availability of staff members and take action to deal with absenteeism(Attendance registers)7. Deal with employee issues, questions and complaints



Applied Knowledge1. Techniques of conducting inspections of work teams to determine fitness for work.2. Standards for acceptable PPE3. Techniques and processes for dealing with unfit employee (Emotional stress, health conditions, intoxication etc.)4. Techniques for conducting start of shift meetings5. Processes and techniques of interpreting management instructions.

Internal Assessment:1. Observe the extent to which the learners conduct the start of shift process and meeting according to the procedures and covers all the required activities2. Observe the extent to which the learners use the appropriate communication processes and behaviours to facilitate the appropriate interactions during the start of shift processes.3. Evaluate that the learners complete the start of shift procedures within a set time period and cover all the required discussions and inspections.4. Evaluate the completeness and accuracy of the records kept of the start of shift process.

313912-001-PM-01-PS02 Identify health, safety and environmental hazards and risks in the lump ore beneficiation environment (includes risk assessments) (Credits: 2)


Given:Given a simulated and controlled plant environment with a range of hazards covering all the major categories of hazards as specified by relevant regulatory requirements and standard checklists/mini risk assessment documents related to a range of typical tasks executed in the plant.

Be Able to:1. Identify all the potential hazards present in the simulated work areas;2. Capture and record all the hazards accurately and correctly on the given hazard identification documents;3. Describe and accurately categorise the risks according to the standard risk assessment processes (Five by five matrix);4. Explain the controls required to mitigate the identified risks;5. Complete a standard hazard assessment report indicating the job specific hazards per job tasks.

Applied Knowledge1. Generally accepted techniques for conducting Hazard and risk assessments (e.g. JHA,HAZOP etc)2. Techniques and processes for identifying and managing hazards and risks (e.g. applyingSLAM (STOP, LOOK, ASSESS and MANAGE)TARP (Trigger, Action, Response, Plan)

Internal Assessment:1. Test understanding of all the applied knowledge - learners must, without reference to learning material explain and describe the use of all the techniques and give examples of how these techniques are applied.2. Learners must describe the process that must be followed to do hazard and risk assessments and indicate how a person must prepare themselves before conducting hazard assessments;3. Learners must, without reference to learning material, identify all the hazards stipulated in the simulation and accurately describe the associated risks and controls indicating the potential consequences of these risks.



313912-001-PM-01-PS03 Ensure that all people entering the environment complies with relevant Safety health and Environmental standards and regulatory requirements. (Credits: 3)


Given:Given: a. Appropriate PPE; b. Specialised Safety Equipment; c. Permits and entrycertification/documents; d. Reporting and related records required; e. policies and procedures for entering work areas in the plant; f. Scenarios of a range of people needing to enter specific work areas, the scenarios must include normal employees, visitors, contractors, maintenance staff and management.

Be Able to:1. Check and verify that the persons are authorised to enter the work area2. Physically check that the persons entering the work area complies with all the health, safety and environmental requirements;3. Complete all the required documentation giving people access to the various work environments;4. Explain the monitoring and reporting processes to ensure compliance with the entry and exit authorizations5. Explain the emergency procedures that must be activated related to people entering the work areas6. Explain any specific rules and procedures to applicable people entering specified areas where required

Applied Knowledge1. Techniques and processes for checking the operating efficiency of specialised/area specific personal safety equipment carried by the individual (Gas monitors, dust monitors, rescue packs etc)2. Processes required for the completion of regulatory required permits and reports

Internal Assessment:1. Identify all PPE and area specific safety equipment related deviations and indicate what must be done to correct them2. Correctly verify all the required authorizations and correctly complete all the documentation.3. Without reference to learning material correctly explain all the required rules, test understanding and deal with questions and objections.

313912-001-PM-01-PS04 Identify problems with the operational efficiency of all health and safety equipment and devices (Ongoing inspections) (Credits: 3)


Given:Given simulated or controlled work environments where all the major/commonly installed safety devices are present and a range of scenarios where the devices are activated.

Be Able to:1. Identify and describe the purpose and application of all of the major devices;2. Describe the actions required when the safety devices are activated;3. Identify defective safety devices and describe the processes to be followed to rectify any defects;4. Test the operational efficiency of all the installed safety devices;5. Explain the normal procedures for the ongoing monitoring and testing of the devices.6. Complete all required checklists and documentation.

Applied Knowledge1. Techniques for inspecting and testing the safety devices



2. Reporting processes to deal with defective safety devices3. Processes for responding to alarms/device activation

Internal Assessment:1. Demonstrate the operation and use of all the specialised/area specific safety equipment according to the manufacturer’s specifications.2. Correctly complete all the required checklists and documentation3. Without reference to learning material describe the various techniques for inspecting and testing the safety devices and correctly explain what must be done where defects in the devices are detected.

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

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 an OD ETDP certificate at NQF level 4 or recognised equivalent


313912-001-PM-02-Monitor and verify the availability of raw materials (NQF Level: 3)



Number Title Credits313912-001-PM-02-PS01 Determine the stock levels of raw material in the storage facilities

on the control system (calculate volumes)4

313912-001-PM-02-PS02 Physically inspect levels of raw material in storage facilities/stockpiles

2

313912-001-PM-02-PS01 Determine the stock levels of raw material in the storage facilities on the control system (calculate volumes) (Credits: 4)


Given:Given an operating control room with appropriate process control systems with various raw materials and various levels of the raw materials.

Be Able to:



1. Access the control systems and identify all the raw materials2. Read and record the levels of all the raw materials3. Select the appropriate raw material storage facilities4. Identify and describe the raw material process flow with all the facilities and equipment in the process5. Manage the levels of raw material in the system (including blending)6. Extract the data required from the system to calculate throughputs, flows and stock levels.7. Calculate and record throughputs, flows and stock levels8. Report and discuss the raw material stock levels

Applied Knowledge1. Techniques to access and operate the appropriate computer based control systems2. Techniques for calculating throughputs, flows and stock levels3. Processes for managing stock levels in the raw material system4. Processes and techniques of manipulating and managing the raw material flow

Internal Assessment:1. Without reference to learning material demonstrate all the techniques for accessing and managing the raw materials using a computer based control system.2. Maintain the required raw material stock levels in the system according to the operating requirements to achieve the set production for a specified production period.3. Correctly calculate and record all the required throughputs, flows and stock levels

313912-001-PM-02-PS02: Physically inspect levels of raw material in storage facilities/stockpiles (Credits: 2)


Given:Given access to a simulated or controlled work environment with an operating raw material process flow containing a range of storage facilities.

Be Able to:1. Explain the interaction (e.g. interlocks, feed rates, capacity etc) between the various components in the system2. Identify and describe the various raw material storage facilities3. Physically inspect each of the storage facilities and determine the level of raw materials in the facility4. Record and report the stock levels in the facilities5. Check the physical condition of the storage facilities and the relevant measuring equipment and instrumentation6. Select the appropriate raw materialApplied Knowledge1. Techniques and processes for the safe inspection of raw material storage facilities2. Techniques and processes for checking instrumentation and measuring equipment3. Techniques for identifying and selecting various raw materials

Internal Assessment:1. Without reference to learning material demonstrate the inspection of raw material storage facilities and explain the reason for the selection and monitoring of raw material levels in an integrated system.2. Evaluate the accuracy of the reported raw material levels



313912-001-PM-03-Facilitate the smooth flow of raw material by means of the material handling and transportation systems and equipment (NQF Level: 3)



Number Title Credits313912-001-PM-03-PS01 Inspect and confirm the availability and running condition of

raw material handling and transporting equipment.2

313912-001-PM-03-PS02 Execute the startup and shut down procedures for all raw material handling and transportation equipment

4

313912-001-PM-03-PS03 Monitor the running of the raw materials handling and transportation equipment

12

313912-001-PM-03-PS01 Inspect and confirm the availability and running condition of raw material handling and transporting equipment. (Credits: 2)


Given:Given a simulated or controlled work environment with specific production targets, production scenarios and a range of material handling and transportation equipment.

Be Able to:1. Select the most appropriate equipment required to achieve the production targets2. Name and describe all the equipment available in the specific production area.3. Oversee the conducting of pre-use inspections on the available equipment and report defects4. Monitor and ensure that the required repairs and maintenance is completed

Applied Knowledge1. Techniques for conducting pre-use inspections on mobile and stationary material handling and transportation equipment2. Interlocking processes between the various components of the raw material supply system

Internal Assessment:1. Without reference to learning material describe the relevant techniques and processes for checking the availability and readiness of raw material handling and transportation equipment.2. Evaluate that all the pre-use checklists have been completed accurately and that all defects and substandard conditions are correctly recorded, reported and that the appropriate corrective actions were taken.



313912-001-PM-03-PS03: Execute the startup and shut down procedures for all raw material handling and transportation equipment (Credits: 4)


Given:Given a simulated or controlled work environment with all the main categories of raw material handling and transportation equipment (Mobile Loaders, conveyors, overhead loaders and transportation equipment, stackers and reclaimers)

Be Able to:1. Execute start up procedures for the applicable equipment using a computer based control system2. Execute manual start up procedures for all the equipment3. Execute all required up and down stream communication for the startup and shut down of the equipment4. Execute normal and emergency shutdown procedures using a computer based control system5. Execute normal and emergency manual shut down procedures

Applied Knowledge1. Techniques for accessing the computer based control system.2. Start up and shut down methodologies and sequences for all the relevant raw material transportation and handling equipment3. Techniques and processes for emergency shut downs4. Manual start up shut down and operating procedures for all stationary raw material handling and transportation equipment

Internal Assessment:1. Without reference to learning materials describe the relevant processes, techniques and sequences correctly indicating the consequences of inappropriate start up and shut down sequences.2. Observe the extent to which the learner complies with the laid down start up, shut down and emergency procedures all procedures must be followed correctly and in the correct sequence.

313912-001-PM-03-PS04 Monitor the running of the raw materials handling and transportation equipment (Credits: 12)


Given:Given a simulated or controlled work environment with all the main categories of raw material handling and transportation equipment (Mobile Loaders, conveyors, overhead loaders and transportation equipment, stackers and reclaimers) and a range of production scenarios and targets.

Be Able to:1. Monitor the performance of the equipment using the computer based control system.2. Take appropriate actions to increase or decrease throughputs and flows to achieve the required production targets.3. Complete all required reports and documentation4. Execute all required up and down stream communication



5. Conduct physical inspections to monitor the performance of the plant and equipment6. Take appropriate action to respond to deviations from standard7. Maintain the appropriate raw material levels in all the storage facilities.8. Conduct problem solving on process related issues and concerns9. Respond to alarms and emergency situation10. Execute the required shift hand over communications and activities

Applied Knowledge1. Problem solving and fault finding techniques2. Communication and shift hand over techniques3. Techniques to manipulate and manage the process to achieve production targets4. Emergency response processes

Internal Assessment:1. Without reference to learning materials describe the relevant processes, techniques and methods correctly giving appropriate examples of what must be done to manage the process optimally in order to achieve the required production targets.2. Observe the extent to which the learner ensures compliance with all the standards, procedures and operating requirements no deviation from the laid down procedures are allowed.3. Evaluate the achievement of the required production results during the specified operating period. At least 80% of the targets must be achieved4. Evaluate the extent to which all required documentation and communication is completed correctly.






313912-001-PM-04-Check and report the quality/parameters of the available raw material (NQF Level: 3)



Number Title Credits313912-001-PM-04-PS01

Take raw material samples from various sample points

2

313912-001-PM-04-PS02

Record and interpret sample results 4

313912-001-PM-04-PS01 Take raw material samples from various sample points (Credits: 2)


Given:Given a simulated or controlled work environment with access to a full range of sampling points, all the raw materials, all the required sampling tools and the appropriate PPE.

Be Able to:1. Identify the correct sampling points to take samples from.2. Select the appropriate sampling methods and tools3. Physically take a range of samples from a full range of sampling points (Liquid samples and solid)4. Place the samples in the appropriate containers and label the samples for analysis by the laboratory.5. Complete all required sampling documentation.

Applied Knowledge1. Techniques for taking various types of samples (Belt cuts, discharge, crusher samples, blended material samples, and equipment efficiency samples)2. Techniques for using specialised sampling equipment3. Processes for applying appropriate sample programmes (Sample size, sample schedules, types of products etc)4. Techniques and processes of labeling and identifying the different samples

Internal Assessment:1. Without reference to learning material explain all the required techniques and give examples of where the various techniques will be used and the consequences of not following the sampling processes correctly.2. Observe the extent to which the learners follow the correct sampling procedures and apply the appropriate safe working practices when taking samples.



313912-001-PM-04-PS02 Record and interpret sample results (Credits: 4)


Given:Given a full range of sample results including accurate and inaccurate sample results.

Be Able to:1. Check the sample results against the set standards and identify deviations.2. Record the received sample results in an appropriate log sheet3. Conduct a trend analysis of the sample results and highlight possible discrepancies4. Determine the possible causes of deviations and report appropriate corrective actions

Applied Knowledge1. Processes for recording sampling results2. Analysis techniques to analyse and interpret sampling results3. Techniques for conducting basic statistical analysis of sample results

Internal Assessment:1. Evaluate the extent to which the learners accurately records, analyses and interprets the sample results according to a set interpretation process and standard. (All results must be correctly recorded and all calculations correctly executed)2. Evaluate that the most appropriate corrective actions were selected and correctly reported.

Provider Accreditation Requirements:






313912-001-PM-05-Determine the raw material requirements to achieve the production targets (NQF Level: 4)




Read and interpret the production requirements and maintenance schedules

2

313912-001-PM-05-PS02

Monitor the feed rates and take appropriate action to correct deviations

4

313912-001-PM-05-PS01 Read and interpret the production requirements and maintenance schedules (Credits: 2)


Given:Given scenarios relating to the operating situation in the plant and the operation and all required production and maintenance schedules and results. (Requirements and actual)

Be Able to:1. Determine the current status of the actual production compared with the required production. (Actual vs target)2. Interpret a forecast of results for the next week based on the current results and trends3. Develop a schedule of actions to ensure that the required production results are achieved in the short and medium term (Shift by shift)

Applied Knowledge1. Basic forecasting techniques2. Planning and scheduling techniques (POLC)3. Problem solving techniques

Internal Assessment:1. Evaluate the extent to which the produced schedule meets the generally accepted standards for scheduling and the feasibility of the proposed forecast and actions achieving the desired results.2. Evaluate the accuracy of the interpreted production results (Plan vs actual)

313912-001-PM-05-PS02 Monitor the feed rates and take appropriate action to correct deviations (Credits: 4)




Given:Given a simulated or controlled work environment providing learners access to a fully operating plant and plant control system covering the conditions relevant to a full shift cycle

Be Able to:1. Access the plant monitoring system and determine the feed rates of raw material at all the stages of the lump ore process for a full shift period.2. Make appropriate process adjustments to ensure that the required outputs and feed rates are maintained3. Report and record all process changes and deviations4. Respond to emergency situations5. Take action to deal with deviations6. Complete the end of shift report

Applied Knowledge1. Techniques for operating a lump ore processing plant2. Techniques for monitoring the feed stock levels and take appropriate action to ensure that the feed stock levels are retained at the appropriate levels.3. Techniques for managing stress

Internal Assessment:1. Give examples of the application of the various techniques to impact positively on the achievement of production results and describe the consequences of non-compliance with the prescribed production processes.2. Observe the extent to which the learners follow all the operating procedures and protocols.3. Observe the appropriate reaction of the learners to emergency situations, breakdowns and deviations.

Provider Accreditation Requirements:






313912-001-PM-06-Start, monitor, control and stop all size reduction equipment (NQF Level: 4)




Inspect all size reduction equipment for defects prior to start up (Includes making appropriate settings) Identify and take corrective action to correct deviations.

3

313912-001-PM-06-PS02

Start up the size reduction equipment and machines 3

313912-001-PM-06-PS01 Inspect all size reduction equipment for defects prior to start up (Includes making appropriate settings) Identify and take corrective action to correct deviations. (Credits: 3)


Given:Given a simulated or controlled work environment with all required size reduction equipment and related services in a process plant.

Be Able to:1. Conduct pre-use inspection of all the size reduction equipment.2. Check the settings of the equipment and take action to correct the settings where required.3. Check the operational readiness and availability of all required auxiliary equipment4. Check the environment to ensure compliance with all health safety and environmental requirements

Applied Knowledge1. Various techniques for checking the settings of the size reduction equipment2. Techniques and documentation to conduct pre-use inspections on equipment

Internal Assessment:1. Observe the extent to which the learners follow all required steps to conduct safe and effective pre use inspections on the equipment and identify all current and potential defects.2. Observe that learners comply with all safety and lock out procedures when checking equipment conditions and settings.3. Evaluate that all checklists and documentation is correctly and accurately completed.

313912-001-PM-06-PS02 Start up the size reduction equipment and machines (Credits: 3)




Given:Given a simulated or controlled work environment where learners have access to a control room and physical access to the equipment in the plant.

Be Able to:1. Communicate the intention to start up and obtain clearance for startup.2. Follow the required control sequence for the remote startup of the size reduction plant.3. Follow the manual start up process and sequence to start up the plant manually.4. Check the functionality of all the equipment on the computer based control system5. Physically observe and check the effective operation of the plant6. Identify and deal with alarm conditions during the startup process.7. Initiate the feed of material into the size reduction plant using the computer based control system8. Initiate the feed manually into the size reduction process.

Applied Knowledge1. Techniques for starting up a size reduction process using a computer based control system2. Techniques and processes for starting up a size reduction process manually

Internal Assessment:1. Test understanding of the full range of possible alarm conditions - Learners must describe all alarm conditions explaining the possible causes and the required action to deal with each of the conditions.2. Observe the extent to which learners follow the laid down start up procedures on the computer and manually. All procedures must be complied with.3. Evaluate the achievement of the appropriate flow of material through the process within a stipulated time period.






313912-002-PM-07-Monitor and control the milling and cycloning processes (NQF Level: 4)



Number Title Credits

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

4

313912-002-PM-07-PS02 Stop, start and monitor the operation of the milling section using a computerised monitoring and control system

4

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)


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.

Critical Activities to be Assessed Externally:

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.

313912-002-PM-07-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:






313912-002-PM-08-Monitor and control the gravity processes (NQF Level: 4)




313912-002-PM-07-PS01 Physically inspect the all gravity separation equipment, identify defects and take corrective actions

4

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


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




313912-002-PM-09-Monitor and control the thickening processes (NQF Level: 4)




313912-002-PM-08-PS01 Physically start the thickening equipment and monitor and control the feed into and through the thickeners

3

313912-002-PM-08-PS02 Start the thickening equipment and monitor and control the feed into and through the thickeners from the control room

3

313912-002-PM-08-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




313912-002-PM-08-PS02 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






313912-002-PM-010-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 process4

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

4

313912-002-PM-10-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. Prepare the filter for the filtering process from a control room3. Physically monitor the sequences of the filtering process4. Physically monitor, control and dispatch the filtration product

Applied Knowledge


313912-002-PM-10-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 needed



5. 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 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



313912-002-PM-10-Monitor and control the leaching processes (NQF Level: 4)




313912-002-PM-10-PS01 Physically monitor the leaching process 4313912-002-PM-10-PS02 Monitor the leaching process from the control room 4



313912-002-PM-10-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 process3. Monitor and control the leaching residence time


Applied Knowledge


313912-002-PM-10-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 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



313912-002-PM-10-PS07 Monitor the agitation process 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 agitation section


Provider Accreditation Requirements: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



313912-002-PM-11-Monitor and control the froth flotation processes (NQF Level: 4)






313912-002-PM-11-PS01 Physically monitor and control the froth flotation process 6313912-002-PM-11-PS02 Monitor and control the feed rate and density from the control

room6

313912-002-PM-11-PS03 Physically monitor and control the feed rate and density313912-002-PM-11-PS04 Physically monitor and control the addition of applicable

reagents into the process313912-002-PM-11-PS05 Physically monitor and control the feed rate and density from the

control room313912-002-PM-11-PS06 Physically start, stop, monitor and control the froth flotation

process313912-002-PM-11-PS07 Start, stop, monitor and control the froth flotation process from

the control room313912-002-PM-11-PS08 Monitor and control the addition of applicable reagents into the

process from the control room313912-002-PM-11-PS09 Physically stop and prepare the flotation process for

maintenance and during emergencies313912-002-PM-11-PS10 Monitor and control the froth flotation process from a control

room

313912-002-PM-11-PS01: Physically monitor and control the froth flotation process (Credits: 6)


Given:

Be Able to:Physically monitor and control the feed rate and densityPhysically monitor and control the addition of applicable reagents into the processPhysically monitor and control the feed rate and density from the control roomPhysically start, stop, monitor and control the froth flotation processStart, stop, monitor and control the froth flotation process from the control roomMonitor and control the addition of applicable reagents into the process from the control roomPhysically stop and prepare the flotation process for maintenance and during emergenciesMonitor and control the froth flotation process from a control room

313912-002-PM-11-PS02 Monitor and control the feed rate and



density from the control room (Credits: 6)

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





313912-002-PM-12-Monitoring and controlling the adsorption processes (NQF Level: 4)






313912-002-PM-12-PS01 Physically monitor the pulp feed rate and density through the adsorption process

6

313912-002-PM-12-PS02 Monitor and control the pulp feed rate and density into the adsorption process

4

313912-002-PM-12-PS03 Physically monitor and control the carbon concentration in the adsorption process

313912-002-PM-12-PS04 Physically monitor and control the counter current transfer of carbon in the adsorption process

313912-002-PM-12-PS05 Monitor and control the counter current transfer of carbon in the adsorption process from the control room

313912-002-PM-12-PS06 Physically transfer loaded carbon to the elution process313912-002-PM-12-PS07 Monitor the transfer of loaded carbon to the elution process from

the control room313912-002-PM-12-PS08 Monitor and control the addition of fresh carbon into the

adsorption system

313912-002-PM-12-PS01: Physically monitor the pulp feed rate and density through the adsorption process (Credits: 6)


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 processMonitor and control the counter current transfer of carbon in the adsorption process from the control roomPhysically transfer loaded carbon to the elution processMonitor the transfer of loaded carbon to the elution process from the control roomMonitor and control the addition of fresh carbon into the adsorption system






313912-002-PM-13-Monitor and control the elution processes (NQF Level: 4)




313912-002-PM-13-PS01 Physically monitor and control the transfer of loaded carbon from the adsorption to and through the elusion process

6

313912-002-PM-13-PS02 Monitor and control the transfer of loaded carbon from the adsorption to the elusion collumn from a control room

4

313912-002-PM-13-PS01: Physically monitor and control the transfer of loaded carbon from the adsorption to and through the elusion process (Credits: 6)


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 process




Applied Knowledge


313912-002-PM-13-PS02 Monitor and control the transfer of loaded carbon from the adsorption to the elusion collumn from a control room (Credits: 4)


Given:

Be Able to:


Applied Knowledge


313912-002-PM-13-PS03 Monitor and control the addition of reagents through the elusion colunm from a control room (Credits: )


Given:

Be Able to:


Applied Knowledge




313912-002-PM-13-PS04 Physically monitor and control the sequence of events in the elution process (Credits: )


Given:



Be Able to:


Applied Knowledge


313912-002-PM-13-PS06 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



313912-002-PM-14-Monitor and control the electro winning/precipitation processes (NQF Level: )




313912-002-PM-14-PS01 Physically monitor the electro winning process 2313912-002-PM-14-PS02 Monitor and control the eluate flow rate through the electro

winning cells from a control room2

313912-002-PM-14-PS01: Physically monitor the electro winning process (Credits: 2)


Given:

Be Able to:Physically prepare the electro winning cells for electro winningPrepare the electro winning cells for electro winning from a control room.Physically monitor and control the total acid concentration in the acid treatment of the carbonMonitor and control the total acid concentration in the acid treatment of the carbon from a control roomPhysically remove the loaded cathodes from the electro winning cellsPhysically remove the concentrate from the cathode and place into appropriate transfer system


Applied Knowledge




313912-002-PM-14-PS02 Monitor and control the eluate flow rate through the electro winning cells from a control room (Credits:2)


Given:

Be Able to:


Applied Knowledge


313912-002-PM-14-PS03 Physically prepare the electro winning cells for electro winning (Credits: )


Given:

Be Able to:


Applied Knowledge


313912-002-PM-14-PS04 Prepare the electro winning cells for electro winning from a control room. (Credits: )




Given:

Be Able to:


Applied Knowledge


313912-002-PM-14-PS05 Physically monitor and control the total acid concentration in the acid treatment of the carbon (Credits: )


Given:

Be Able to:


Applied Knowledge


313912-002-PM-14-PS06 Monitor and control the total acid concentration in the acid treatment of the carbon from a control room (Credits: )


Given:

Be Able to:




Applied Knowledge


313912-002-PM-14-PS07 Physically remove the loaded cathodes from the electro winning cells (Credits: )


Given:

Be Able to:


Applied Knowledge


313912-002-PM-14-PS08: Physically remove the concentrate from the cathode and place into appropriate transfer system (Credits:)


Given:

Be Able to:


Applied Knowledge




313912-002-PM-14-PS09 Monitor and control the electro winning 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 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






313912-002-PM-16-Physically monitor the make-up, storage and distribution of reagents (NQF Level: )




313912-002-PM-16-PS01 Identify and safely handle a range of reagents 8313912-002-PM-16-PS02 Oversee the receiving, offloading and storage of reagents313912-002-PM-16-PS03 Make up a range of reagents manually and using automated

processes

313912-002-PM-16-PS01 Identify and safely handle a range of reagents (Credits: 8)


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






313912-002-PM-17-Monitor and control the regeneration process (NQF Level: )




313912-002-PM-17-PS01 Physically monitor and control the regeneration of eluted material

4

313912-002-PM-17-PS02 Monitor and control the regeneration of eluted material from a control room

4

313912-002-PM-17-PS01: Physically monitor and control the regeneration of eluted material (Credits: 4)


Given:

Be Able to:


Applied Knowledge




313912-002-PM-17-PS02 Monitor and control the regeneration of eluted material from a control room (Credits: 4)


Given:

Be Able to:




Applied Knowledge







313912-002-PM-18-Monitor and control the preparation of tailings for re-use (NQF Level: )




313912-002-PM-18-PS01 Physically neutralize the chemicals in the tailings313912-002-PM-18-PS02 Monitor and control the transport of tailings for purposes of re-

use

313912-002-PM-18-PS01 Physically neutralize the chemicals in the tailings (Credits: )


Given:

Be Able to:


Applied Knowledge


313912-002-PM-18-PS02 Monitor and control the transport of tailings for purposes of re-use (Credits: )


Given:

Be Able to:




Applied Knowledge







313912-002-PM-19-Monitor and control the disposal/transfer of tailings (NQF Level: )




313912-002-PM-19-PS01 Start, stop and operate the tailings transfer equipment

313912-002-PM-19-PS01 Start, stop and operate the tailings transfer equipment (Credits: )


Given:

Be Able to:


Applied Knowledge







313912-002-PM-20-Monitor and control the disposal of waste material (Bags, buckets, wood chips etc) (NQF Level: )




313912-002-PM-20-PS01 Oversee the collection and transport of waste material313912-002-PM-20-PS02 Oversee the collection of liquid hazardous waste material in road

transport tankers

313912-002-PM-20-PS01 Oversee the collection and transport of waste material (Credits: )


Given:

Be Able to:


Applied Knowledge1. Process of separating waste into the correct disposal bins2. Consequences of the incorrect handling of waste material




313912-002-PM-20-PS02 Oversee the collection of liquid hazardous waste material in road transport tankers (Credits: )


Given:

Be Able to:


Applied Knowledge







SECTION 3C: WORK EXPERIENCE MODULE SPECIFICATIONS

List of Work Experience Module Specifications


313912-002-WM-01 Exposed to risk management processes for all areas of the plant 0313912-002-WM-02 Exposure to the full range of raw material preparation processes

and equipment used on the specific site.0

313912-002-WM-03 Exposure to the milling and cycloning processes 0313912-002-WM-04 Exposure to the thickening processes 0313912-002-WM-05 Exposure to the filtration processes 0313912-002-WM-06 Exposure to the leaching processes 0313912-002-WM-07 Exposure to the full range of waste handling and disposal

processes used on the specific site.0

Total Work Experience Credits: 0



313912-002-WM-01 - Exposed to risk management processes for all areas of the plant

Purpose of the Module

List of Experiences included in this module


313912-002-WM-01-01 Successful completion of the company specific on job plant induction313912-002-WM-01-02 Participate in the completion of two continuous risk assessments per shift

for a period of four weeks.313912-002-WM-01-03 Participate in daily safety/start up meetings for a period of four weeks313912-002-WM-01-04 Conduct planned inspections in all areas of the plant for a four week shift

period313912-002-WM-01-05 Participate in the conducting of planned task observations for designated

tasks in the plant313912-002-WM-01-06 Participate in emergency drills (at least one)313912-002-WM-01-07 Meet company requirements regarding first aid certificate313912-002-WM-01-08 Identify and report incidents, substandard acts and substandard

conditions (At least one in a four week shift cycle)313912-002-WM-01-09 Perform lockout procedures according to the site specific standards (At

least one per shift cycle)313912-002-WM-01-10 Participate in incident/accident investigations (At least one)313912-002-WM-01-11 Conduct at least two inspections of areas defined as confined spaces313912-002-WM-01-12 Conduct at least two inspections of areas where harnesses and/or fall

arrest equipment is required

313912-002-WM-01-01 Successful completion of the company specific on job plant induction

Guidelines for Work Experience

Contextual Workplace Knowledge

Supporting Evidence

313912-002-WM-01-02 Participate in the completion of two continuous risk assessments per shift for a period of four weeks.





Supporting Evidence

313912-002-WM-01-03 Participate in daily safety/start up meetings for a period of four weeks



Supporting Evidence

313912-002-WM-01-04 Conduct planned inspections in all areas of the plant for a four week shift period



Supporting Evidence

313912-002-WM-01-05 Participate in the conducting of planned task observations for designated tasks in the plant



Supporting Evidence

313912-002-WM-01-06 Participate in emergency drills (at least one)





Supporting Evidence

313912-002-WM-01-07 Meet company requirements regarding first aid certificate



Supporting Evidence

313912-002-WM-01-08 Identify and report incidents, substandard acts and substandard conditions (At least one in a four week shift cycle)



Supporting Evidence

313912-002-WM-01-09 Perform lockout procedures according to the site specific standards (At least one per shift cycle)



Supporting Evidence

313912-002-WM-01-10 Participate in incident/accident investigations (At least one)





Supporting Evidence

313912-002-WM-01-11 Conduct at least two inspections of areas defined as confined spaces



Supporting Evidence

313912-002-WM-01-12 Conduct at least two inspections of areas where harnesses and/or fall arrest equipment is required



Supporting Evidence

Criteria for Workplace Approval:

Physical Requirements:

Human Resources Requirements:

Legal Requirements:

Exemptions:



313912-002-WM-02 - Exposure to the full range of raw material preparation processes and equipment used on the specific site.




313912-002-WM-02-01 Take actions to manage the levels of raw material in the storage facilities on the control system (Two four week shift cycles)

313912-002-WM-02-02 Physically inspect levels of raw material in storage facilities/stockpiles313912-002-WM-02-03 Execute the site specific minor maintenance required on belt conveyors

and ore transport systems

313912-002-WM-02-01 Take actions to manage the levels of raw material in the storage facilities on the control system (Two four week shift cycles)



Supporting Evidence

313912-002-WM-02-02: Physically inspect levels of raw material in storage facilities/stockpiles



Supporting Evidence

313912-002-WM-02-03 Execute the site specific minor maintenance required on belt conveyors and ore transport systems





Supporting Evidence




Legal Requirements:

Exemptions:

313912-002-WM-03 - Exposure to the milling and cycloning processes




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

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

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



Supporting Evidence

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





Supporting Evidence




Legal Requirements:

Exemptions:

313912-002-WM-04 - Exposure to the thickening processes




313912-002-WM-04-01 Physically execute the work required in the section for a period of five shifts

313912-002-WM-04-01: Physically execute the work required in the section for a period of five shifts



Supporting Evidence




Legal Requirements:



Exemptions:

313912-002-WM-05 - Exposure to the filtration processes








Supporting Evidence




Legal Requirements:

Exemptions:



313912-002-WM-06 - Exposure to the leaching processes








Supporting Evidence




Legal Requirements:

Exemptions:



313912-002-WM-07 - Exposure to the full range of waste handling and disposal processes used on the specific site.






Legal Requirements:

Exemptions:

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