Mineral Beneficiation Process Controller (Material Handler)

The purpose of this qualification is to prepare a learner to operate as a Mineral Beneficiation Process Controller (Material Handler). Completion of this qualification will enable the learner to gain the knowledge, develop the skills and be exposed to the work experience required to work in a process plant and to monitor and control all the generic raw material and final product handling and processing equipment. Learners will gain the knowledge, skills and experience to operate a plant in a safe and efficient manner and to apply the required communication skills when working in a processing plant environment. Mineral Beneficiation Process Controllers: (Material Handlers) monitor and control the operational efficiency of the Materials Handling and Comminution equipment and processes in a mineral beneficiation plant. A qualified learner will be able to: • Ensure compliance with all Occupational Health, Safety and Environmental requirements to minimise the operational risk in a mineral beneficiation/extraction plant. • Monitor and control the availability of materials to achieve production targets in a mineral beneficiation/extraction plant for a designated production period.

Process control is a function that exists in a range of industries and operations. It encapsulates physical work on the plant with the relevant processing equipment as well as distant process controlling using computerised control equipment. This Occupational Certificate is the first part of a suite of qualifications. It covers the generic component of the process control operations, in other words those components where material is received, stockpiled and moved to the next stage of the process. The next stage can be within the same operation but in some cases it is part of a totally different operation. The mineral beneficiation process control value chain includes the following main elements: • Raw material receipt and stockpiling/storing. • Raw material transportation, preparation and blending. • Mineral Processing (Hydrometallurgy, Smelting, Calcining). • Processed product handling and stockpiling. • Processed product preparation and dispatching. All mineral beneficiation processes involve the above-mentioned activities. The front and back end of those processes are similar in most operations (Raw Materials and Finished Products). Another part of the process control function that is generic to most industries, is the requirements regarding Occupational Health and Safety. This Occupational Certificate is designed to meet the industry demands regarding these generic functions. It will create structured learning pathways for a large component of Process Controllers and it will serve as a compulsory entry qualification that will form the basis for specialising in materials preparation and the processing of the various minerals (Hydrometallurgy, Smelting and Calcining). The qualification covers the work executed by the inside and outside Process Controllers, the learning covers both NQF Levels 3 and 4 learning and the qualification is pitched at NQF Level 4. This qualification is an entry requirement for the specialisation areas. (Materials Preparation, Mineral Processing: Hydrometallurgy, Mineral Processing: Smelting and Mineral Processing: Calcining). The qualification covers all the basics of equipment start-up, shut-down and operational monitoring from a physical (in the plant) and from a control room perspective. One of the cornerstones of the National Development Plan is a focus on the further beneficiation of our mineral resources. This will require investment in new plants and there will be a need for additional Process Controllers. This qualification and the four specialisations will support the national strategy and it will create a pool of learners that can enter the Mineral Processing fields. As the National strategy progresses, these qualifications will become more important. From an industry perspective, this qualification will create common standards and it will enhance safety and productivity in the workplace.

Recognition of Prior Learning (RPL): RPL for access to the external integrated summative assessment: Accredited providers and approved workplaces must apply the internal assessment criteria specified in the related Curriculum document to establish and confirm prior learning. Accredited providers and workplaces must confirm prior learning by issuing a Statement of Results or certifying a Work Experience Record. RPL for access to the qualification: Accredited providers and approved workplaces may recognise prior learning against the relevant entry requirements. Entry Requirements: • NQF Level 2 with Mathematical Literacy.

• Conduct risk assessments in process operations and identify appropriate actions to deal with deviations and mitigate risks.
• Describe and explain the legal, organisational and moral responsibilities of all stakeholders regarding the personal health, safety and environmental conditions in areas where minerals are being processed/beneficiated.
• Describe the role, importance, type, frequency and process of conducting inspections in a process operation.
• Explain how all safety, health and environmental information and requirements must be communicated, reported and enforced, and what actions must be taken to deal with deviations, defects, incidents and accidents.
• Interpret and explain typical mineral processing/beneficiation process flows.
• Execute the fundamental scientific calculations required in a typical process operation.
• Describe the fundamental operating principles of the mechanical equipment and processes relevant to typical mineral processing/beneficiation operations.
• Use computerised process control systems to monitor and control mineral beneficiation processes, deal with deviations and respond to emergencies.
• Apply leading practices for effective control room administration.
• Identify deviations from the standard and adjust the process accordingly.