National Occupational Certificate: Mineral Beneficiation Process Controller (Preparation/ Concentration/ Hydrometallurgy/ Pyrometallurgy)

Purpose

The purpose of this qualification is to prepare a learner to operate as a Mineral Beneficiation Process Controller.

Mineral Beneficiation Process Controllers operate, monitor, and control the operation and operational efficiency of mineral beneficiation process plant, facilities, equipment, and related resources. The qualifying learner will know the functioning and operating requirements to achieve production targets, health, safety, environmental and security requirements, and will be able to control the plant productively and safely.

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/solid-liquid separation plant.
• Operate, monitor, and control mineral beneficiation and process plant, facilities, equipment, and related resources.
• Troubleshoot process problems.
• Communicate production targets effectively to manage the process.

Qualifying learners will know how to operate, monitor, and control mineral beneficiation plant safely and competently. In addition, with this qualification, they can advance their careers within the Mining and Minerals Sector.

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 Beneficiation" in this context 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. Recovery rates and cost implications relating to minerals extraction processes must be optimised to ensure the ongoing viability of the producer.

The end products of these processes are metals or metal compounds that can be beneficiated in a wide variety of applications, for example:

• Gold used for jewellery, currency, electronic components, dentistry.
• Base metals like copper and aluminium for conductors, zinc for anti-corrosion coatings, cobalt for paint, and lead for battery poles.
• Platinum group metals for jewellery and catalysts.
• Mineral sand products (titanium etc.) for steel hardening, paint pigments and special alloys.
• Lump Ore Beneficiation done to increase the grade of the ore to minimise the cost of subsequent transport and further processing.

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, a need has arisen to capacitate this qualification with the required knowledge and skills to cope with demands brought about by new technologies as well as statutory and legislative requirements. In addition, in terms of mining legislation, Mineral Beneficiation Process Controllers who are appointed must be qualified to comply with statutory and mandatory requirements.

This qualification replaces Occupational Certificates which have reached their end of date registration on 2023 -06-30.

Society will benefit from the qualification by the comfort of knowing that beneficiation processes are carried out by qualified learners who are conscious about safety of fellow workers and are aware of the impact of their actions towards the environment and the country at large. The sector will benefit from the qualification from being served by qualified Mineral Beneficiation Process Controllers who are proficient in their work, thus resulting in improved quality service, increased production levels and a safer working environment, contributing towards the growth of the economy, as well as society, by way of local and foreign investments and sale of products which will lead to building the economy of the country.

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.

Typical learners for the qualification are employed in the Mining and Minerals Sector and will be qualified Plant Operators working in a metallurgical plant.

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

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

The reflection on learning pathway towards qualifications in other Sub-Frameworks was identified as a possibility under diagonal articulation.

Collaboration with relevant stakeholders

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

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.

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.

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

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.

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 3 qualification with Communication and Mathematics.

Or

• An NQF Level 3 Intermediate Occupational Certificate Mineral Processing Plant Operator (Part of pack).

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

Knowledge Modules

• 313912-000-01-KM-01: Occupational Health, Safety, and Environment, NQF Level 4, 8 Credits.
• 313912-000-01-KM-02: Mineral Beneficiation, NQF Level 4, 8 Credits.
• 313912-000-01-KM-03: Plant Management, NQF Level 4, 8 Credits.
• 313912-000-01-KM-04: Supervision, NQF Level 4, 8 Credits.

Select One (1) Module from Category A

• 313912-000-01-KM-05: Mineral Preparation, NQF Level 4, 16 Credits.
• 313912-000-01-KM-06: Mineral Concentration, NQF Level 4, 16 Credits.
• 313912-000-01-KM-07: Hydrometallurgy, NQF Level 4, 16 Credits.
• 313912-000-01-KM-08: Pyrometallurgy, NQF Level 4, 16 Credits.

Total number of credits for Knowledge Modules: 48

Practical Skill Modules

• 313912-000-01-PM-01: Monitor Occupational Health, Safety, and Environmental Compliance, NQF Level 4, 8 Credits.

Select One (1) Module from Category A

• 313912-000-01-PM-02: Operate, Monitor, and Control Preparation Plant and Equipment, NQF Level 4, 24 Credits.
• 313912-000-01-PM-03: Operate, Monitor, and Control Concentration Plant and Equipment, NQF Level 4, 24 Credits.
• 313912-000-01-PM-04: Operate, Monitor, and Control Hydrometallurgical Plant and Equipment, NQF Level 4, 24 Credits.
• 313912-000-01-PM-05: Operate, Monitor and Control Pyrometallurgical Plant and Equipment, NQF Level 4, 24 Credits.

Total number of credits for Practical Skill Modules: 32

Work Experience Modules

Select One (1) Module from Category A

• 313912-000-01-WM-01: Preparation Plant Operations, NQF Level 4, 40 Credits.
• 313912-000-01-WM-02: Concentration Plant Operations, NQF Level 4, 40 Credits.
• 313912-000-01-WM-03: Hydrometallurgical Plant Operations, NQF Level 4, 40 Credits.
• 313912-000-01-WM-04: Pyrometallurgical Plant Operations, NQF Level 4, 40 Credits.

Total number of credits for Work Experience Modules: 40

1. Conduct risk assessments in process operations and identify appropriate actions to deal with deviations and mitigate risks.
2. Apply mineral processing fundamental knowledge to operate, monitor, and control the plant.
3. Apply mineral processing technique to operate, monitor, and control the plant.
4. Coordinate troubleshooting activities carried within the mineral processing plant.
5. Facilitate communication process within the operation of the mineral processing plant.

Associated Assessment Criteria for Exit Level Outcome 1

ELO 1: Conduct risk assessments in process operations and identify appropriate actions to deal with deviations and mitigate risks.

• Apply fundamental knowledge and understanding of problem-solving, occupational health, safety, and the environmental requirements, context-specific mineral processing, process plant operation, monitoring and control, and statutory, regulatory, and organisational compliance.
• Validate descriptions of typical hazard identification and risk assessment systems and processes and indicate how these systems are applied at the learners' work site.
• Identify and describe all the hazards given in a relevant mineral beneficiation process and include an explanation of what actions must be taken to mitigate the associated risks.
• Demonstrate the physical ability to conduct risk assessments in mineral processing environments following all the required procedures and standards.

Associated Assessment Criteria for Exit Level Outcome 2

ELO 2: Apply mineral processing fundamental knowledge to operate, monitor, and control the plant.

• Apply fundamental knowledge and understanding of problem-solving, occupational health, safety and the environmental requirements, context-specific mineral processing, process plant operation, monitoring and control, and statutory, regulatory, and organisational compliance.
• Carry out plant operation, monitoring, and control functions, in accordance with requirements.
• Identify and describe the implications and consequences of identified deviations; and remedial action required.
• Complete and analyse sampling in accordance with requirements.
• Identify and report defects, damage, or deviations; shut down or isolate the plant, or section of the plant and/or equipment in a safe manner if required.
• Identify and report changes in occupational health, safety, environment, or operating conditions in accordance with statutory, regulatory, and organisational requirements.
• Apply continuous risk assessment.
• Carry out communication and reporting activities, as required.

Associated Assessment Criteria for Exit Level Outcome 3

ELO 3: Apply mineral processing technique to operate, monitor, and control the plant.

• Apply fundamental knowledge and understanding of problem-solving, occupational health, safety and the environmental requirements, context-specific mineral processing, process plant operation, monitoring and control, and statutory, regulatory, and organisational compliance.
• Carry out plant operation, monitoring, and control functions, in accordance with requirements.
• Describe the implications and consequences of identified deviations; and remedial action required.
• Complete and analyse sampling, in accordance with requirements.
• Identify and report defects, damage, or deviations; shut down or isolate the plant, or section of the plant and/or equipment in a safe manner if required.
• Identify and report changes in occupational health, safety, environment, or operating conditions, in accordance with statutory, regulatory, and organisational requirements.
• Apply continuous risk assessment.
• Carry out communication and reporting activities, as required.

Associated Assessment Criteria for Exit Level Outcome 4

ELO 4: Coordinate troubleshooting activities carried within the mineral processing plant.

• Assess the corrective and preventative actions implemented in the different sections of the plant.
• Implement or undertake processes/ activities that evaluate that corrective and preventative actions are achieving the required objectives.
• Update records and report coordinated actions/ responses.

Associated Assessment Criteria for Exit Level Outcome 5

ELO 5: Facilitate communication process within the operation of the mineral processing plant.

• Use oral and written communication channels to convey intended outcomes.
• Communicate fluently and understandably, in accordance with requirements.
• Communicate production targets effectively to manage the process.

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.

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.