Mineral Beneficiation Process Controller (Mineral Processor Smelting)

The purpose of this qualification is to prepare a learner to operate as a Mineral Beneficiation Process Controller (Mineral Processor - Smelting). A Mineral Processor: Smelting, monitors and controls the hot processes for beneficiating mineral ore, Ferro-manganese (FeMn) and FerroChrome (FeCr). A qualified learner will be able to: • Monitor and control the pyro-metallurgical processes in a mineral beneficiation smelting operation.

This qualification is in direct support of the national mineral beneficiation strategy and is constructed according to the needs expressed by industry. It will provide portability and career opportunities for Process Controllers working in a number of strategically important mining sectors. Smelting is a form of extractive metallurgy; its main use is to produce a base metal from its ore. This includes production of silver, iron, copper and other base metals from their ores. Smelting makes use of heat and a chemical reducing agent to decompose the ore, driving off other elements as gasses or slag and leaving just the metal base behind. The reducing agent is commonly a source of carbon, such as coke or charcoal. The carbon (or carbon monoxide derived from it) removes oxygen from the ore, leaving behind the elemental metal. The carbon is thus oxidised in two stages, producing first carbon monoxide and then carbon dioxide. As most ores are impure, it is often necessary to use flux, such as limestone, to remove the accompanying rock gangue as slag. Learners who enter this qualification will be well versed in all the Occupational Health and Safety issues; they will have experience of working with process control equipment; and they will have been exposed to the operating dynamics of material handling equipment.

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: • Occupational Certificate: Mineral Beneficiation Process Controller (Materials Handling) Level 4.

• Monitor and control mineral beneficiation processes associated with a Pyro-Metallurgical Smelter.
• Interpret sample results.
• Identify measuring and monitoring instrumentation on the plant, read and interpret the information and take appropriate corrective action.
• Identify and deal with potential up- and down-stream implications and problems.