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SOUTH AFRICAN QUALIFICATIONS AUTHORITY 
REGISTERED UNIT STANDARD THAT HAS PASSED THE END DATE: 

Monitor and control an electrowinning process 
SAQA US ID UNIT STANDARD TITLE
263636  Monitor and control an electrowinning process 
ORIGINATOR
Chemical Industries SGB 
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY
-  
FIELD SUBFIELD
Field 06 - Manufacturing, Engineering and Technology Engineering and Related Design 
ABET BAND UNIT STANDARD TYPE PRE-2009 NQF LEVEL NQF LEVEL CREDITS
Undefined  Regular  Level 3  NQF Level 03  15 
REGISTRATION STATUS REGISTRATION START DATE REGISTRATION END DATE SAQA DECISION NUMBER
Passed the End Date -
Status was "Reregistered" 		 2018-07-01  2023-06-30  SAQA 06120/18 
LAST DATE FOR ENROLMENT LAST DATE FOR ACHIEVEMENT
2024-06-30   2027-06-30  

In all of the tables in this document, both the pre-2009 NQF Level and the NQF Level is shown. In the text (purpose statements, qualification rules, etc), any references to NQF Levels are to the pre-2009 levels unless specifically stated otherwise.  

This unit standard does not replace any other unit standard and is not replaced by any other unit standard. 

PURPOSE OF THE UNIT STANDARD 
Learners who demonstrate competence as described in the outcomes of this unit standard will be able to monitor and control an electrowinning process using any of the locally available equipment configurations. The process ranges from the base metal feed to the electrowinning process up to the stripping of the metal and the discharge of the spent electrolyte product.

The qualifying learner is able to:
  • Explain the fundamental principles applicable to an electrowinning process.
  • Monitor and control the different ancillary systems interacting with the electrowinning process.
  • Monitor and control the quality standards of process materials in the electrowinning process.
  • Monitor and control the electrowinning process.
  • Monitor the safety, health, environment, security and housekeeping aspects of the electrowinning process. 
    		•

    LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    Learners accessing this unit standard will have demonstrated competence against mathematics and literacy at NQF Level 2 or equivalent. 

    UNIT STANDARD RANGE 
  • The typical context of this unit standard covers an electrowinning process using any of the locally available equipment configurations.
  • The process ranges from the base metal feed to the electrowinning process up to the stripping of the metal and the discharge of the spent electrolyte product.
  • This unit standard can apply to a range of electrowinning applications, including copper (Cu), nickel (Ni), cobalt (Co) and zinc (Zn).

    Range statements, which are applicable to the unit standard titles, specific outcomes and assessment criteria are found beneath the applicable assessment criteria. 
    		•

    Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Explain the fundamental principles applicable to an electrowinning process. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    The purpose of an electrowinning process is explained in terms of the final product manufactured. 

    ASSESSMENT CRITERION 2 
    The principles of an electrowinning process are explained by making use of a generic flow diagram. 

    ASSESSMENT CRITERION 3 
    The electrowinning process is explained in relation to its supplier's and customer's processes. 

    ASSESSMENT CRITERION 4 
    The flow of material through the electrowinning process is traced and all equipment is identified using standard industry terminology. 

    ASSESSMENT CRITERION 5 
    The purpose and functioning of each piece of equipment used in the electrowinning process is explained in terms of its role in the overall process. 
    ASSESSMENT CRITERION RANGE 
    Equipment include but is not limited to cells, pumps, samplers, holding tanks, filter presses, transformers, bus bars, rectifiers, overhead cranes, stripping machine, etc. used in the process.
     

    ASSESSMENT CRITERION 6 
    The functions of all chemicals used within the electrowinning process are explained in terms of their chemical and physical properties. 
    ASSESSMENT CRITERION RANGE 
    Chemicals may include but are not limited to sulphuric acid, ammonia and Nalco as well as any other chemicals within the process.
     

    SPECIFIC OUTCOME 2 
    Monitor and control the different ancillary systems interacting with the electrowinning process. 
    OUTCOME RANGE 
    Ancillary systems refer to the interface between mechanical equipment, electrical equipment, instrumentation and utilities and the electrowinning process. It only includes those parts of each ancillary system which interact directly with the electrowinning process and not the full ancillary system. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Mechanical equipment used in the electrowinning process is identified and described in terms of purpose and application. 
    ASSESSMENT CRITERION RANGE 
    Mechanical equipment may include but is not limited to bulk handling equipment, conveying equipment, weighing equipment, storage equipment, transport equipment and packaging equipment.
     

    ASSESSMENT CRITERION 2 
    Electrical equipment used in the electrowinning process is identified and described in terms of purpose and application. 
    ASSESSMENT CRITERION RANGE 
    Electrical equipment may include but is not limited to electrical motors, electrical switch, switchgear, interlocks, transformers, bus bars, rectifiers, overhead cranes, stripping machine used in the process.
     

    ASSESSMENT CRITERION 3 
    Instrumentation used in the electrowinning process is identified and described in terms of purpose and application. 
    ASSESSMENT CRITERION RANGE 
    Instrumentation may include but is not limited to the key process indicators, control valves, controllers and interlocks used to monitor and control the process.
     

    ASSESSMENT CRITERION 4 
    Utilities used in the electrowinning process are identified and described in terms of purpose and application. 
    ASSESSMENT CRITERION RANGE 
    Utilities may include but is not limited to air, steam, electricity, vacuum, demineralised water and cooling water.
     

    ASSESSMENT CRITERION 5 
    Typical ancillary equipment problems within the electrowinning process are discussed and solutions offered in accordance with workplace procedures. 

    ASSESSMENT CRITERION 6 
    Ancillary systems are monitored and any deviations from operating parameters are corrected in accordance with operating procedures. 

    SPECIFIC OUTCOME 3 
    Monitor and control the quality standards of process materials in the electrowinning process. 
    OUTCOME RANGE 
    Process materials include all raw materials, products, chemicals and any additives forming part of the electrowinning process. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    The properties of process materials are explained in terms of key characteristics. 

    ASSESSMENT CRITERION 2 
    The purpose of process material quality control procedures as well as the consequences of not adhering to these procedures are explained with regards to the impact thereof on the final product produced. 

    ASSESSMENT CRITERION 3 
    The quality requirements of raw materials, chemicals and additives are explained according to general and workplace specifications. 
    ASSESSMENT CRITERION RANGE 
    Specifications are defined by equipment operating instructions. Specifications may include but is not limited to impurities contained in the final metal products and the electrolyte and acid concentrations.
     

    ASSESSMENT CRITERION 4 
    Typical raw material problems and its impact on the final product properties and costs are discussed in terms of the purpose of the process. 
    ASSESSMENT CRITERION RANGE 
  • Raw material problems may include but is not limited to impurities nickel & iron, solids contents incorrect volumes and blends and incorrect concentration of copper solutions.
  • Final product properties may include but are not limited to the metal as identified by the workplace quality control system.
     
    		•

    ASSESSMENT CRITERION 5 
    Corrective action to be taken in the case of non-conforming raw materials is discussed in accordance with workplace procedures. 

    ASSESSMENT CRITERION 6 
    Product variations are evaluated and corrective action taken in accordance with workplace procedures. 
    ASSESSMENT CRITERION RANGE 
  • "Product" includes the metal as well as the spent electrolyte product.
  • "Variations" includes but are not limited to impurities contained within the metal, metal thickness, porosity and adhesion to the cathodes.
     
    		•

    SPECIFIC OUTCOME 4 
    Monitor and control the electrowinning process. 
    OUTCOME NOTES 
    The monitoring and controlling of the electrowinning process should be performed according to operational requirements and standard operating procedures. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    The electrowinning process is monitored and parameters recorded in accordance with workplace procedures. 

    ASSESSMENT CRITERION 2 
    The impact of process deviations on the product properties, throughput and safety is explained in terms of final products and costs. 
    ASSESSMENT CRITERION RANGE 
    Process variables may include but are not limited to tank and sump levels, temperature, process flow rate, Copper solution concentrations, acid concentration, KA value, extraction draught.
     

    ASSESSMENT CRITERION 3 
    Typical equipment problems within the electrowinning process are discussed and solutions offered in accordance to workplace procedures. 
    ASSESSMENT CRITERION RANGE 
    Equipment problems may include but are not limited to line blockages, faulty valves, insufficient steam, faulty rectifier, transformer problems, electrical failure and a lack of draught in the fume extraction.
     

    ASSESSMENT CRITERION 4 
    Deviations in process conditions are evaluated and corrective action taken to return to normal conditions in accordance with workplace procedures. 
    ASSESSMENT CRITERION RANGE 
    Process deviations may include but are not limited to low or high tank and sump levels, incorrect temperatures, flow rates, process flow rate, copper solution concentrations, acid concentration, KA value steam pressure and a lack of draught.
     

    SPECIFIC OUTCOME 5 
    Monitor the safety, health, environment, security and housekeeping aspects of the electrowinning process. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    The organisation's safety, health, environmental and security policies are discussed with specific reference to own responsibility. 

    ASSESSMENT CRITERION 2 
    Risks in the electrowinning process plant emanating from the process, chemicals, equipment and operational conditions are discussed in terms of their possible impact on personnel, equipment, production and the environment. 

    ASSESSMENT CRITERION 3 
    Preventative and corrective measures used to avoid such incidents are discussed and solutions offered in accordance to workplace procedures. 

    ASSESSMENT CRITERION 4 
    Security requirements pertaining to the electrowinning process plant are explained according to security procedures. 

    ASSESSMENT CRITERION 5 
    Safety, health, environmental and security risks are addressed in accordance with situational requirements and relevant policies. 

    ASSESSMENT CRITERION 6 
    Housekeeping requirements are discussed and implemented in the workplace in accordance with situational requirements and relevant policies. 


    UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
  • An assessor, accredited with a relevant NQF Level 4 or higher qualification, will assess the learner's competency. Only an Assessor with suitable first hand experience in process operations will assess the learner's competency.
  • Anyone assessing a learner or moderating the assessment of a learner against the qualification must be registered as an assessor with the relevant Education, Training, Quality, Assurance (ETQA) Body, or with an ETQA that has a Memorandum of Understanding with the relevant ETQA.
  • Any institution offering learning that will enable the achievement of this qualification must be accredited as a provider with the relevant Education, Training, Quality, Assurance (ETQA) Body, or with an ETQA that has a Memorandum of Understanding with the relevant ETQA.
  • Assessment and moderation of assessment will be overseen by the relevant Education, Training, Quality, Assurance (ETQA) Body, or by an ETQA that has a Memorandum of Understanding with the relevant ETQA, according to the ETQA's policies and guidelines for assessment and moderation.
  • Moderation must include both internal and external moderation of assessments, unless ETQA policies specify otherwise. Moderation should also encompass achievement of the competence described in the associated unit standards.
  • Anyone wishing to be assessed against this qualification may apply to be assessed by any assessment agency, assessor or provider institution that is accredited by the relevant ETQA. 
    		•

    UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE 
    Qualifying learners understand and can:

    Explain the names, functions and locations of:
  • All items of installed equipment.
  • Raw material/s.
  • Finished product/s.

    Describe the properties and characteristics of:
  • Raw material/s.
  • Product/s.
  • Process equipment.
  • Auxiliary equipment.
  • Process system/s.

    Explain the purpose of the:
  • Process, in terms of product/s, efficiencies and quality.

    Explain the causes, effects and implications of:
  • Process variables.
  • Raw material variables (suppliers).
  • Product variables (customers).
  • Not complying with quality standards.
  • Not complying with standard operating procedures.

    Demonstrate procedures and techniques of:
  • Monitoring and controlling the process.
  • Recording and reporting data.

    Explain the regulations, legislation, agreements and policies related to:
  • Standard Operating procedures.
  • Quality specifications. 
    		•

    UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
    The learner is able to identify and solve problems in which responses display that responsible decisions, using critical and creative thinking, have been made by:
  • Identifying and addressing variations in ancillary system operation.
  • Identifying and addressing variations in material quality.
  • Identifying and addressing variations in the electrowinning process.
  • Bringing all deviations into control.

    Refer to the following Specific Outcome(s):
  • Monitor and control the quality standards of process materials in the electrowinning process.
  • Monitor and control the electrowinning process. 
    		•

    UNIT STANDARD CCFO WORKING 
    Work effectively with others as a member of a team, group, organisation or community by:
  • Maintaining sound relations with co-workers.

    Refer to the following Specific Outcome(s):
  • Monitor and control the quality standards of process materials in the electrowinning process.
  • Monitor and control the electrowinning process. 
    		•

    UNIT STANDARD CCFO ORGANISING 
    The learner is able to organise and manage himself and his activities responsibly and effectively by:
  • Working to achieve consistent results required by the process/customers.

    Refer to the following Specific Outcome(s):
  • Monitor and control the quality standards of process materials in the electrowinning process.
  • Monitor and control the electrowinning process. 
    		•

    UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organise and critically evaluate information by:
  • Using various sources of information pertaining to the electrowinning process, including basic scientific and engineering theory.
  • Monitoring and recording process, product and equipment variables.
  • Carrying out physical quality checks and tests.
  • Explaining the impact of non-conforming materials in terms of final products and costs.
  • Describing the relationship of the process to suppliers, customers and the overall electrowinning process.

    Refer to all Specific Outcomes. 
    		•

    UNIT STANDARD CCFO COMMUNICATING 
    Communicate effectively by using mathematical and/or language skills in the modes of oral and/or written presentations during:
  • Recording of variables and actions taken to rectify.
  • Responding to questions and requests for additional information.
  • Liaising with relevant operational support units.
  • Drawing and interpreting diagrams and sketches.
  • Completing relevant documentation in accordance with workplace requirements.

    Refer to all Specific Outcomes. 
    		•

    UNIT STANDARD CCFO SCIENCE 
    Use science and technology effectively and critically, showing responsibility towards the environment and health of others by:
  • Monitoring the process.
  • Bringing process, product and equipment variables into control.

    Refer to the following Specific Outcome(s):
  • Monitor and control the quality standards of process materials in the electrowinning process.
  • Monitor and control the electrowinning process. 
    		•

    UNIT STANDARD CCFO DEMONSTRATING 
    Demonstrate an understanding of the world as a set of related systems by:
  • Explaining the purpose of the process as well as the relationship to the supplier and customer's processes.

    Refer to all Specific Outcomes. 
    		•

    UNIT STANDARD CCFO CONTRIBUTING 
    Contribute to the full personal development of each learner and the social and economic development of the society at large by:
  • Understanding the role of monitoring plant and process in a processing environment and the effect it has on the growth and development of the organisation, its customers and employees.

    Refer to all Specific Outcomes. 
    		•

    UNIT STANDARD ASSESSOR CRITERIA 
    N/A 

    REREGISTRATION HISTORY 
    As per the SAQA Board decision/s at that time, this unit standard was Reregistered in 2012; 2015. 

    UNIT STANDARD NOTES 
    N/A 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Elective  78528   National Certificate: Chemical Operations  Level 3  NQF Level 03  Passed the End Date -
    Status was "Reregistered"     		 2023-06-30  As per Learning Programmes recorded against this Qual 


    PROVIDERS CURRENTLY ACCREDITED TO OFFER THIS UNIT STANDARD: 
    This information shows the current accreditations (i.e. those not past their accreditation end dates), and is the most complete record available to SAQA as of today. Some Primary or Delegated Quality Assurance Functionaries have a lag in their recording systems for provider accreditation, in turn leading to a lag in notifying SAQA of all the providers that they have accredited to offer qualifications and unit standards, as well as any extensions to accreditation end dates. The relevant Primary or Delegated Quality Assurance Functionary should be notified if a record appears to be missing from here.
     
    NONE 


    All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.