Intermediate Occupational Certificate: Mineral Processing Plant Operator (Preparation/ Concentration/ Hydrometallurgy/ Pyrometallurgy)

Purpose

The purpose of this qualification is to prepare a learner to operate as a Mineral Processing Plant Operator.

A Mineral Processing Plant Operator carries out the activities to operate, monitor, and control mineral processing plant and equipment operations. The qualifying learner will know the functioning and operating requirements for the plant and equipment to achieve production targets, health, safety environmental and security requirements, and will be able to operate the plant productively and safely.

A qualified learner will be able to

• Ensure occupational health, safety, and environmental compliance.
• Operate, monitor, and control mineral processing plant and equipment.

The qualifying learner will know how to safely operate mineral processing plant. In addition, qualifying learners can advance their learning and careers within the mineral processing plant control operations.

Graduate attributes

• Honesty
• Integrity
• punctuality
• Time management
• Self-motivation
• Responsibility
• Accountability
• Interpersonal relations
• Ethical behaviour
• well organised
• Self-confidence
• Confidentiality

Rationale

The ever-changing technology and demands exerted by globalisation require the workforce to have the requisite skills that will enable them to operate at the level of their counterparts, globally.

"Minerals Processing" refers to the extraction of valuable minerals contained in mined ore and the production of related products, or enriched concentrates, for further processing or sale. Processes employed in the recovery of gold, platinum, uranium, base metals, coal, iron ore, diamonds, manganese etc. are provided for in this qualification. The end products of these processes are metals or metal compounds that can be beneficiated in a wide variety of applications. Recovery rates and cost implications relating to minerals extraction processes must be optimised to ensure the ongoing viability of the producer. Production of these commodities is of tremendous benefit to the economy, as well as society, by way of local and foreign investments and the sale of products.

Furthermore, due to innovation in the use of information technology in the mining industry, coupled with the need to comply with statutory and legislative requirements, learners entering this qualification will develop the knowledge and skills required to work in a process plant to monitor and control all the generic raw material and processing equipment - to cope with demands brought about by new technologies as well as statutory and legislative requirements.

Currently, there is no registered qualification for Mineral Processing Plant Operators. The need for the development of this qualification was identified during the scoping meeting where the mining and minerals sector's stakeholders expressed a need to develop an NQF Level 3 qualification, that will bridge the gap between a skills programme at NQF Level 2 and the National Occupational Certificate: Minerals Beneficiation Process Controller qualification, which is under review.

Society will benefit from the qualification as mineral processing plants are mostly located near rural areas and many previously disadvantaged individuals from the rural areas are employed to work in these plants. This qualification will help improve their employability.

This qualification will benefit the mining sector and society as it will equip operating personnel with the technical competencies to be able to work safely and productively; optimise minerals extraction operations and thereby contributing to the stability and growth of the country's economy. Social development and economic transformation are enhanced through efficient mineral extraction and career development and personal job satisfaction of operating personnel is facilitated through the learning process used to achieve the competency specified.

Learners registering for this qualification will typically be working within the mining industry or are qualified operators in a particular section within a Mineral Processing Plant. The qualification has various specialisations for learners to follow. It will be possible for learners to articulate between the respective specialisations. The inclusion of the technical-related qualification is to ensure that learners who enrol into this qualification cope with the learning required to complete the qualification.

The typical learning pathway in mineral processing and beneficiation operations would be to begin with

• the Skills Programme(s) for Mineral Processing Plant Operators at NQF Level 2.
• Control Room Operator, at NQF Level 3 (Optional).
• Mineral Processing Plant Operator, at NQF Level 3.
• Mineral Beneficiation Process Controller, at NQF Level 4.
• Plant/Shift Foreman/Supervisor.
• Plant Superintendent.

Collaboration with relevant stakeholders

• Workplace Practitioners,
• Assessors and moderators,
• Private Training Providers,
• Skills Development Facilitators and
• Curriculum Development Specialists.

Recognition of Prior Learning (RPL)

RPL for Access to Training

Learners may use the RPL process to gain access to training opportunities for a programme of learning, qualification, part-qualification, or skills programme if they do not meet the formal, minimum entry requirements for admission. RPL assessment provides an alternative access route into a programme of learning, qualification, part-qualification, or skills programme.

Such an RPL assessment may be developed, moderated, and conducted by the accredited Skills Development Provider which offers that specific qualification/part qualification/skills programme. Such an assessment must ensure that the learner is able to display the equivalent level of competencies required for access, based on the NQF level descriptors.

RPL for exemption from modules

For exemption from modules through RPL, learners who have gained the stipulated competencies of the modules of a programme of learning, qualification, part-qualification, or skills programme through any means of formal, informal, or non-formal learning and/or work experience, may be awarded credits towards relevant modules, and gaps identified for training, which is then concluded.

Learners who have gained the stipulated competencies of the modules of a programme of learning, qualification, part-qualification, or skills programme through any means of formal, informal, or non-formal learning and/or work experience, may be awarded credits towards relevant modules, and gaps identified for training, which is then concluded.

RPL for Access to the External Integrated Summative Assessment (EISA)

A valid Statement of Results is required for admission to the EISA in which confirmation of achievement is provided that all internal assessment criteria for all modules in the related curriculum document have been achieved.

Upon successful completion of the EISA, RPL learners will be issued with the QCTO certificate for the qualification, part-qualification, or skills programme. Quality Partners are responsible for ensuring the RPL mechanism and process for qualifications and part-qualification is approved by the QCTO.

Entry Requirements

An NQF Level 2 qualification with Communication and Mathematics.

And

An NQF Level 2 Plant Operator Skills Programme.

Or

An NQF Level 2 Mineral Processing qualification

This qualification is made up of compulsory Knowledge, Practical Skill and Work Experience Modules

Knowledge Modules

• 711201-000-00-KM-01, Occupational Health, Safety, and the Environment, NQF Level 3, 16 Credits.
• 711201-000-00-KM-02, Plant Maintenance, NQF Level 3, 8 Credits.
• 711201-000-00-KM-03, Teamwork and Supervision, NQF Level 3, 8 Credits.

Total number of credits for Knowledge Modules: 32

Practical Skill Modules

• 711201-000-00-PM-01, Manage Time and Work Processes, NQF Level 3, 4 Credits.
• 711201-000-00-PM-02, Prepare for, and Perform Minor Process Maintenance, NQF Level 3, 16 Credits.

Select one (1) module from Category A

• 711201-000-00-PM-03, Operate and Control Preparation Plant, NQF Level 3, 32 Credits.
• 711201-000-00-PM-04, Operate and Control Concentration Plant, NQF Level 3, 32 Credits.
• 711201-000-00-PM-05, Operate and Control Hydrometallurgical Plant, NQF Level 3, 32 Credits.
• 711201-000-00-PM-06, Operate and Control Pyrometallurgical Plant, NQF Level 3, 32 Credits.

Total number of credits for Practical Skill Modules: 52

Work Experience Modules

Select one (1) module from Category A

• 711201-000-00-WM-01, Preparation Plant Operations, NQF Level 3, 36 Credits.
• 711201-000-00-WM-02, Concentration Plant Operations, NQF Level 3, 36 Credits.
• 711201-000-00-WM-03, Hydrometallurgical Plant Operations, NQF Level 3, 36 Credits.
• 711201-000-00-WM-04, Pyrometallurgical Plant Operations, NQF Level 3, 36 Credits.

Total number of credits for Work Experience Modules: 36

1. Apply basic knowledge of health, safety and environmental hazards and risk requirements, and apply health, safety and environmental, and hazard identification and risk assessment processes and procedures.
2. Apply basic knowledge and skills of mineral processing, preparation plant and equipment; and operational procedures to operate the mineral processing plant.
3. Perform troubleshooting activities in the mineral processing plant.
4. Apply communication skills to achieve operational target.

Associated Assessment Criteria for Exit Level Outcome 1

ELO 1: Apply basic knowledge of health, safety and environmental hazards and risk requirements, and apply health, safety and environmental, and hazard identification and risk assessment processes and procedures.

• Explain the importance of identifying and responding to various kinds of hazards.
• Explain how to respond to emergencies.
• Explain legal and procedural compliance for ensuring occupational health, safety and environmental compliance.

Associated Assessment Criteria for Exit Level Outcome 2

ELO 2: Apply basic knowledge and skills of mineral processing, preparation plant and equipment; and operational procedures to operate the mineral processing plant.

• Describe and explain legal and procedural compliance for operation of the plant and working.
• Follow the correct sequence of operations.
• Operate plant and equipment within specified limits.
• Identify and report any defects, damage or deviations and the plant, or shut down or isolate section of the plant and/or equipment in a safe manner.
• Identify and report changes in environment or conditions - continuous risk assessment.
• Apply safety, health and environmental measures and responsibilities in accordance with requirements.

Associated Assessment Criteria for Exit Level Outcome 3

ELO 3: Perform troubleshooting activities in the mineral processing plant.

• Identify problems.
• Analyse problems using root cause analysis.
• Identify the roots cause(s).
• Correct and eliminate the root cause(s).

Associated Assessment Criteria for Exit Level Outcome 4

ELO 4: Apply communication skills to achieve operational target.

• Fluent and understandable communication in accordance with requirements.
• Conduct communication correctly through various channels (tools).
• Communicate operational targets to production personnel.

Integrated Assessment

Formative Assessments conducted internally

Formative assessments are conducted throughout the training of learners. A range of formal, non-formal, and informal ongoing assessment activities are used to focus on teaching and learning outcomes to improve learner attainment.

Formative assessments are conducted continuously by the facilitator to feed into further learning, to identify strengths and weakness, and to ensure the learner's ability to apply knowledge, skills and workplace experience gained.

Formative Assessments are conducted by the accredited Skills Development Provider (SDP), and a variety of ongoing assessment methods may be used, for example, quizzes, assignments, tests, scenarios, role play, interviews. Continuous feedback must be provided.

Integrated Summative Assessments conducted Internally

Integrated Assessment involves all the different types of assessment tasks required for a particular qualification, part-qualification, or occupational skills programme, such as written assessment of theory and practical demonstration of competence. To achieve this, the Internal Assessment Criteria (IAC) for all modules as found in the QCTO curriculum document must be followed.

An accredited SDP should implement a well-designed, formal, relevant, final internal Summative Assessment strategy for all modules to prepare learners for the EISA. These assessments evaluate learning achievements relating to the achievement of each module of the relevant components of the qualification, part-qualification, or skills programme.

Internal Summative Assessments are developed, moderated, and conducted by the SDP at the end of each module or after integration of relevant modules, e.g. applied knowledge tests, workplace tasks, practical demonstrations, simulated tasks/demonstrations, projects, case studies, etc.

The results of these final formal summative assessments must be recorded. These results, which include the Statement of Work Experience results, where applicable, contribute to the Statement of Results (SoR) that is a requirement for admission to the EISA. An SoR, using the template provided by the Quality Partner, is issued by the accredited SDP for qualifications and part-qualifications. The SDP must produce a valid Statement of Results for each learner, indicating the final result and the date on which the competence in each module, of each component, was achieved. Learners are required to produce this SoR, together with their ID document or alternative ID document, at the point of the EISA.

External Integrated Summative Assessment (EISA)

The Quality Partner is responsible for the management, conduct and implementation of the External Integrated Summative Assessment (EISA), in accordance with QCTO set standards. Competence in the EISA is a requirement for certificating a learner.

For entrance into the EISA, the learner requires a valid Statement of Results issued by the accredited institution indicating:

The attainment of all modules for the Knowledge, Practical and Work Experience modules.

Or

The attainment of all modules for the Knowledge and Application Components.