Production Operator - Middelburg at Samancor Chrome

PURPOSE OF THE JOB

To safely operate the Pelletising and Sintering plant (PSP) both in the field and at the control room through the SCADA system

BALANCED SCORECARD PILLARS, ROLES AND RESPONSIBILITIES: 

SAFETY, HEALTH, ENVIRONMENT AND QUALITY

• Participate and comply with SHEQ requirements (SHEQ Toolbox)
• Control environmental emissions 

CUSTOMERS

• Ensure Customer Satisfaction
• Liaise with internal suppliers and external service providers when required

BUSINESS PROCESSES

• Metallurgical Processes:
• Oversee all metallurgical processes in the plant
• Monitor and control the process
• Monitor all critical parameters from SCADA and analyse trends
• Conduct visual inspections around plant
• Monitor bin land bunker levels (ores, steel balls, bentonite and chemicals)
• Monitor and control a metallurgical plant/ the process from a control room and in the field
• Control/ operate the water reticulation in a metallurgical process
• Control/ operate the gas cleaning system to minimise pollution and water treatment
• Oversee the feeding and conveying system
• Ensure correct dosing of feed to the plant
• Inspect the furnace and auxiliary systems and action non-conformances
• Control the furnace cooling system

Transferring:

• Transfer material by means of a belt conveyor
• Transfer fluids by means of pumping
• Control feed rate by monitoring scales 
• Control feed distribution by means of a conveyor system
• Control the water reticulation in a metallurgical process
• Monitor compressed air supply

Separating/Filtering/Grinding:

• Separate material by means of a vibrating screen
• Separate material by means of a thickener
• Separate liquid from solids by means of a vacuum disc filter
• Remove air-borne dust by means of a scrubber
• Grind material by means of a ball mill
• Control the milling operation by monitoring the critical parameters
• Control the in-mill slurry density by manipulating water addition
• Monitor all critical parameters around the mill from SCADA
• Oversee filter cake production

Material Handling:

• Off-load bentonite, caustic soda and nitric acid safely from a tanker into a bulk storage facility
• Handle nitric acid and caustic soda safely in a metallurgical plant
• Maintain steel ball hopper

Furnace operation: 

• Control and monitor all furnace critical parameters 
• Control furnaces start and stopping procedures
• Maintain plant production levels
• Drive plant efficiency
• Control and monitor all safety alarms linked to the furnace
• Be aware of all maintenance related work around the plant

Analysing:

• Sample feed streams and analyse moisture and carbon content
• Analyse process data for furnace stability
• Sample ball mill product for specific gravity determination
• Determine the strength of green and sintered pellets
• Determine filter cake grain size
• Determine tumbler test values of pellets
• Determine the particle size distribution of the sintered pellets
• Sample sintered pellets and ores for chemical analysis
• Test pH of process water and report deviations
• Determine slurry density 

Maintenance:

• Conduct First Line Maintenance 
• Prepare the furnace for maintenance
• Create notifications for maintenance work
• Lock out and obtain isolation permits
• Assist in general plant maintenance when required
• Conduct basic hand tool maintenance

Unplanned Interventions:

• Perform isolation and lockout
• Attend to breakdown
• Capture all data related to the stoppage to aid in determining the root cause (Complete detail on the log sheet) 

Reporting:

• Update the log sheets and the MES system
• Report on plant failures via SAP notifications

General:

• Maintain high housekeeping standards
• Be prepared to work in a hot and dusty environment
• Work overtime as and when required
• Any other related tasks require

Requirements

Minimum qualifications:

• Grade 12 or N3 or N3 that is equivalent to a Grade 12/ Matric (4x Technical subjects or 4x Business subjects and 2x Language subjects)
• Three (3) years’ relevant experience in a production environment

Advantageous:

• Acting experience in a Furnace Operator position
• Metals Production Learnership/ Skills Programme 
• Experience in working at Furnaces
• PSP (Pelletising) experience

BEHAVIOURAL COMPETENCIES: 

• Safety Awareness
• Initiative
• Managing Work
• Results Orientation
• Customer Focus
• Operational Problem solving and decision making
• Work Standards
• Interpersonal Relationships
• Communication
• Adaptability
• Contributing to Team Success

WORKPLACE COMPETENCIES: 

• Skills: 
• Microsoft Office
• Samancor Chrome Systems (IMS, EBMS, ChromeDoc, MES, SCADA)
• Proficient in English communication in both speaking and writing
• Able to communicate to various operators/ artisans simultaneously with a two-way radio
• Able to function well under pressure
• Able to take charge from the control room and help over two-way radio communication
• Always alert

Knowledge: 

• Demonstrate basic knowledge of analysing data
• Demonstrate an understanding of the Pelletiser/ Sintering process
• Extended knowledge of the Outokumpu pelletising and sintering operations
• Extended knowledge on process flow cause and effect
• Demonstrate an understanding to interpret data and information provided by operators
• Demonstrate an understanding of the major risks around the plant area