Metals Production & Related Process Training

Metals Production Department

Metals Production training department offers a variety of courses to the Metals Production industries (Smelters) i.e.: National Certificate: Metals Production – NQF Level 2,3 & 4 Metals Production Skills Programme Metals Production RPL Programme Pelletizing & Sintering Plant Training

Purpose of the course

The purpose of these courses is to enable the operator of a smelting industry to perform their duties to the utmost of their ability with optimum results.

Course Objective

The objective is to provide the operator with the tools and knowledge to efficiently operate the smelting furnaces, to understand the metallurgy of the process and to produce a quality product in a safe and cost effective manner.

Course Benefits

Following these courses, the operator will have the knowledge to maximise the output in a metals production process and handle himself in a professional manner as an empowered employee. The organization will have a pool of readily available operators (in the case of a skills programme) from which it can draw whenever a need arises. Previously disadvantaged employees will be afforded the opportunity to get their skills and experience recognised through Recognition of Prior Learning (RPL)

Requirements

Metal Mining Training Interventions is accredited with both the MerSETA and the MQA to offer these programmes. As a requirement on commencement of the course, the following documents are required: Original Certified copy of highest qualification Original certified copy of highest qualification Contract of Employment with employer letter head Metals Production – we keep the metal rolling by closing the skills gap in the smelting industries!

1. National Certificate: Metals Production NQF level 2

Description:

his Qualification is for any individual who is, or wishes to be, involved in a metals production environment. The Qualification contains all the skills, knowledge, values and attitudes required by a learner who needs mainly to be able to perform a range of activities within a specific metals production environment to support a particular process like extracting, melting, refining, casting, rolling, shearing, forging and other metallurgical processes. An individual acquiring this Qualification will be able to contribute towards the smooth and efficient operation of the production processes in the metals production sector. For those who have been in the workplace for a long time, this qualification represents part of the RPL process to acknowledge workplace skills acquired without the benefit of formal education or training.


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2. National Certificate: Metals Production NQF level 3

Description:

This qualification is for any individual who is, or wishes to be, involved in a metals production environment and be able to perform a range of activities to operate and maintain process equipment for a particular process or operation within a specific metals production environment. Such processes or operations will include extracting, melting, refining, casting, rolling, shearing, forging and other metallurgical processes. In general, individuals at this level in the metal production environment will operate a furnace, casting machine or a converter among other process machines or equipment. These are large and complex machines which require training a learner over an extended period of time before s/he acquires sufficient competence to operate them. An individual acquiring this qualification will be able to contribute towards the smooth and efficient operation of the production processes in the metal production sector.


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3. National Certificate: Metals Production NQF level 4

Description:

This is the third qualification in a series designed for learners who want to follow a career in a ferrous or non-ferrous metals production working environment. The series outlines a learning progression from NQF level 2 to NQF level 4 for learners learning and working in for example, the iron and steel, tin, aluminium, graphite, copper, and zinc production industries. It reflects the skills, knowledge and understanding required to participate effectively in processes within the above-mentioned industries, whether in small, medium or large operations. For those who have been in the workplace for a long time, this qualification represents part of the RPL process to acknowledge workplace skills acquired without the benefit of formal education or training.


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4. Metals Production Skills Programme

Description:

The skills programme was compiled from the Qualification metals production NQF level 2 (SAQA ID: 49018) and consists of some of the Core, Fundamental and electives unit standards in the level 2 qualification. The skills programme is to equip the learner enabling him /her to fill the gaps in the plant to fill vacant positions, with competent employees, on the tap floors and at the transport department as they cover all the relevant licences as well.


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Separate Training Modules for a Production Process

5. Smelter Operations, Prepare the furnace for Maintenance

Description:

Understand the importance of preparing the furnace for maintenance and pre start inspections.


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6. Smelter Operations, Operate a Gas Cleaning System

Description:

The learner will be able to operate all task specific equipment and machinery and plan the work activity to remove airborne dust by operating a gas cleaning system


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7. Smelter Operations, Inspecting Furnace Equipment And Monitoring Auxiliaries

Description:

Understand the furnace operator is the key figure of responsibility for the furnace and auxiliary equipment


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8. Smelter Operations, Controlling the slipping of electrodes to maintain electrode lengths

Description:

Understand the theory of self baking or self forming paste electrodes as well as prefabricated carbon electrodes and the application for electrical Arc furnace


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9. Smelter Operations, Controlling The Furnace Cooling System

Description:

Understand the importance and necessity for cooling of electrical circuits and furnace operation


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10. Smelter Operations, Controlling electrical operation of the furnace to smelt the burden efficiently

Description:

Understand basic electrical principles and advanced electrical formulas and apply basic electrical formulas for furnace power consumption


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11. Smelter Operations, Prepare Casting Equipment

Description:

This material will help the learner identify and operate all task specific equipment and machinery and plan the work activity to prepare casting equipment.


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12. Smelter Operations, Prepare a ladle

Description:

To ensure how to prepare a ladle and to maximize the life of a ladle ensuring a quality product


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13. Smelter Operations, Handling Molten Material

Description:

The learner will be able to perform the correct maintenance, and operational procedures when handling molten material


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14. Smelter Operations, Controlling the proportions of raw materials required for the smelting process

Description:

By the time the course has finished the learner will be able to perform maintenance and operational procedures in the required time while controlling the proportions of raw material


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15. Smelter Operations, Control solid paste level to compensate for electrode consumption

Description:

The learner will understand, identify and operate all task specific equipment and machinery and plan the work activity to control solid paste levels


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16. Smelter Operations, Charging and stoking the furnace in order to obtain the desired operating condition

Description:

The learner will understand and be able to perform correct maintenance and operational procedures within the required time while stoking the Furnace


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17. Smelter Operations, Casting Molten Metal

Description:

Understand ,identify and operate all task specific equipment and machinery to cast molten metal


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18. Smelter Operations, Prepare the Tap floor

Description:

The training will help the learner to understand identify and operate all task specific equipment and machinery and plan the work activity to prepare the tap floor


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19. Smelter Operations, Opening a Tap hole by means of a Tap hole drill

Description:

To inform the learner of the importance of drilling a furnace tap hole correctly and in a safe manner.


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20. Smelter Operations, Tapping a furnace by means of lancing

Description:

The process of opening the tap hole by means of an oxygen lances


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21. Smelter Operations, Tap furnace to recover the melted product

Description:

To understand and perform the correct maintenance and operational procedures while operating the equipment and tap the furnace correctly


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22. Smelter Operations, Closing the tap hole by means of a mud gun

Description:

To understand and be able to perform the correct maintenance and operational procedures within the required time while closing the taphole with a mud gun


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23. Smelter Operations, Maintain the tap hole

Description:

To know how to maintain a taphole to maximise the life of the taphole ensuring a quality product and a safe continuous process


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