Process Controller- Extractive Metallurgy

Curriculum Document
Curriculum Code / Curriculum Title
313912-003 / Mineral Beneficiation Process Controller: (Extraction Metallurgy)

DRAFT CURRICULUM – JUNE 2014Page 1

Process Controller- Extractive Metallurgy

Table of Contents

SECTION 1: CURRICULUM OVERVIEW

Occupational Information

Associated Occupations

Occupation or Specialisation Addressed by this Curriculum

Alternative Titles used by Industry

Curriculum Structure

Knowledge Subjects

Practical Skills Modules

SECTION 2: OCCUPATIONAL PROFILE

Title: Mineral Beneficiation Process Controller: (Extractive

Metallurgy)

OFO Code

Occupational Purpose

Occupational Tasks

Task Details

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 toachieve 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 wastehandling processes in an extractive metallurgical plant.(NQF Level: 3)

SECTION 3: CURRICULUM COMPONENT SPECIFICATIONS SECTION

3A: KNOWLEDGE SUBJECT SPECIFICATIONS

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

313912-002-KS-02: Extraction Metallurgy

SECTION 3B: PRACTICAL SKILL MODULE SPECIFICATIONS

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

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

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)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

SECTION 3C: WORK EXPERIENCE MODULE SPECIFICATIONS

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

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

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

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

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

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

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

DRAFT CURRICULUM – JUNE 2014Page 1

Process Controller- Extractive Metallurgy

SECTION 1: CURRICULUM OVERVIEW

Occupational Information

Associated Occupations

Occupation or Specialisation Addressed by this Curriculum

Alternative Titles used by Industry

Process Controller- Extractive Metallurgy

Curriculum Information

Relation of this Curriculum to the Occupation and Qualification

Progression

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

Number / Title / NQF Level / Credits
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 / 0
313912-002-PM-06 / Monitor and control the milling and cycloning processes / 8
313912-002-PM-07 / Monitor and control the gravity processes / 4
313912-002-PM-08 / Monitor and control the thickening processes / 0
313912-002-PM-09 / Monitor and control the filtration processes / 8
313912-002-PM-10 / Monitor and control the leaching processes / 8
313912-002-PM-11 / Monitor and control the froth flotation processes / 12
313912-002-PM-12 / Monitoring and controlling the adsorption processes / 10
313912-002-PM-13 / Monitor and control the elution processes / 10
313912-002-PM-14 / Monitor and control the electro winning/precipitation processes / 4
313912-002-PM-15 / Physically take and analyse samples for extraction metallurgical processes / 0
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 / 8
313912-002-PM-18 / Monitor and control the preparation of tailings for re-use / 0
313912-002-PM-19 / Monitor and control the disposal/transfer of tailings / 0
313912-002-PM-20 / Monitor and control the disposal of waste material (Bags, buckets, wood chips etc) / 0

Total Practical Skill Credits: 80

Work Experience Modules

Number / Title / NQF Level / Credits
313912-002-WM-01 / Exposed to risk management processes for all areas of the plant / 0
313912-002-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 / 0
313912-002-WM-04 / Exposure to the thickening processes / 0
313912-002-WM-05 / Exposure to the filtration processes / 0
313912-002-WM-06 / Exposure to the leaching processes / 0
313912-002-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

Process Controller- Extractive Metallurgy

SECTION 2: OCCUPATIONAL PROFILE

Title: Mineral Beneficiation Process Controller: (Extractive

Metallurgy)

OFO Code: 313912-003

Occupational Purpose

Operate, 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 Details

TASK 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 beneficiationprocesses

Context

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

TASK 02: Monitoring and controlling the availability and preparation of raw materials toachieve 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 thespecific 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 wastehandling 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 specificsite.

Process Controller- Extractive Metallurgy

SECTION 3: CURRICULUM COMPONENT SPECIFICATIONS SECTION

3A: KNOWLEDGE SUBJECT SPECIFICATIONS

List of Knowledge Subjects for which Specifications are included

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 / 2

Total Knowledge Credits: 31

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

Purpose of the Knowledge Subject

The 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:

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

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;

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

Topics included in this subject:

TOPIC NUMBER / TOPIC TITLE / WEIGHT / CREDITS
313912-002-KS-02:01 / Concepts and principles of mineralogy (Intermediate) / 4
313912-002-KS-02:02 / Tailing disposal processes (Basic) / 3
313912-002-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)

TOTAL TOPIC CREDITS: 29

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 South

Africa

2. Identify the various minerals in terms of their physical characteristics

3. Describe the potential hazards associated with the processing of the different minerals

4. Give examples of how the various physical properties of minerals impact on the beneficiation/extraction processes

Process Controller- Extractive Metallurgy

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

Internal Assessment Criteria:

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 re- cycling and storage of tailings;

7. Describe the operating principles of tailings dams and indicate how this impacts on the position of depositing tailings into the dams;

8. Describe the impact of pumping distances on the effective transfer of tailings material into a tailings storage facility.

Internal Assessment Criteria:

313912-002-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. Mass

5. Explain the principle of thermodynamics as applied in extraction metallurgy

6. Explain the law of conservation of energy

7. Describe the principles of corrosion in a process plant and the actions required to minimise corrosion

Internal Assessment Criteria:

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.

Internal Assessment Criteria:

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;