Resume - Senior Plant Metallurgist, 16 years operations & commissioning ‘hands-on’ experi...

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Resume #85405

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Objective
Looking for a Senior Plant Metallurgist/Plant Superintendent role in a metallurgical processing operation (Copper, Cobalt, Nickel leaching, SX-EW) where my technical, operations and business skills will add value.

Education
2006 - 2008
Masters In Business Leadership
University of South Africa

1996
Principles Of Management
Organisational Training and Development

January 1996 – December 1996
Certificate in Business Functions
Zimbabwe Institute of Management

1989 - 1992
BSc.Engineering Hons. in Metallurgy
University of Zimbabwe
(Awarded a Union Carbide scholarship in 1991)

1987 - 1988
GCE 'A' Level (Cambridge)
St. Ignatius College, Harare, Zimbabwe

1983 – 1986
GCE 'O' Level (Cambridge), Harare, Zimbabwe
St. Ignatius College, Harare, Zimbabwe:

Career History

1.SEPTEMBER 2004 – PRESENT
Kasese Cobalt Company Limited
Uganda
SENIOR PLANT METALLURGIST
Background
- The plant has a complex hydro-metallurgical circuit that includes the first base metal bio-leach circuit in the world, solvent extraction, electrowinning as well as the supporting utility sections.
Responsibilities
- Provide technical and operational support to the process; identifying, evaluating and implementing projects/plant modifications.
- Investigating plant problems/ unusual occurrences and presentation in form of reports.
- Take on the role of Standby Manager.
- Stand in for the Plant Manager.
- Supervise 3 Plant Metallurgists and a Metallurgical Clerk.
- Coaching Metallurgists.
- Ensuring the refinery produces budgeted quantity of metal at the right quality and within the cost budget.
- Ensuring that safety standards are met and plant problems are resolved quickly.
- Ensuring plant modifications/projects are aligned to business strategy.
- Chairing production meetings and disciplinary enquiries
- Involvement in project/modifications selection and prioritization
- Preparing refinery budget.
- Safety, Health, Environment and loss prevention.
- Dealing with suppliers of reagents, plant and equipment.
- Liaising with consultants on plant problems/modifications/projects.
- Presentation of Refinery performance report at monthly general meeting.
- Recruiting technical and senior operations personnel
- Liaising with other departments – maintenance, laboratory, environment and safety.
Achievements
- Resolution of the perennial high copper problem in cobalt cathode resulting in increased revenue of US$793 664 per annum.
- Optimisation of acid consumption resulting in a saving of US$270 000 per annum
- SX Circuit process reconfiguration by de-commissioning ZnSX while not compromising on metal quality resulting in cost savings on reagents and maintenance to the tune of US$504 000 per annum.
- Championed project aimed at replacing CoSX extractant Cyanex 272 with a cheaper extractant Ionquest 290. The plant trial was successful and the new reagent has since been introduced in the main CoSX circuit. It has been in use for 2 years and cost savings of up to US$600 000 per annum are being realized.
- Reduced unit costs by 2.0% through optimisation of acid consumption on the plant.
- Introduction of HAZOP (Hazard and Operability) studies which has improved the quality of modifications.
- Introduced cost-cutting initiative meetings – a number of initiatives from these meetings have been introduced and have played a significant role in helping the company survive the global financial crisis.
- Played a key role through discussions/presentations to make the workforce aware on the importance of cutting costs – what it means to the company's bottom line vis-à-vis to the global recession. This initiative has resulted in a shift of culture.

2.AUGUST 2003 - AUGUST 2004
Anglo Platinum
South Africa
PROCESS METALLURGIST
Responsibilities
- Providing technical support to a platinum base metals (PGMs, Cu, Ni, Co Pressure Leach; Cu, Ni EW; CoSX) refinery by performing plant modifications, troubleshooting, process optimization and process standby.
- Guiding and coaching graduate metallurgists.
Achievements
- Resolved the problem of low grade copper in tankhouse.
- Worked with a colleague and successful managed to characterize the PGMs primary leach.
Reason for leaving
- To take up a more challenging role in Uganda.

3.MARCH 2000 - JULY 2003
Botswana Ash
Botswana
PROCESS ENGINEER
Responsibilities
- Providing process-engineering support to the plant operating staff.
- Metallurgical accounting.
- Organising the quarterly stocks survey as well as the preparation of the survey report
- Processes optimisation.
- Plant modifications; Identifying, evaluating and implementing projects.
- Operations trouble shooting.
- Unusual occurrence investigations.
- Safety, Health, Environment and loss prevention.
- Guiding and coaching Graduate Process Engineers.
- Chairing disciplinary enquiries.
Achievements
- Resolution of the high carbon problem in soda ash which had a significant impact on the bottom line.
- Successfully managed the implementation a project that led to a 5% increase in product recovery.
Reason for leaving
- To go back to the PGM base metals industry.

4.JANUARY 1998 – FEBRUARY 2000
BHP World Minerals
Hartley Platinum Mine (Zimbabwe)
BMR SUPERINTENDENT
(Promotion)
Background
- Beginning of 1998 saw the Base Metal Refinery shifting from a commissioning to an operational phase.
- The Base Metal Refinery attained 90% of design capacity before it was closed in February 2000 due to mining difficulties.
Responsibilities
- Supervised 4 Process Shift Foremen, 2 Metallurgists and a Metallurgical Clerk.
- Each shift had a complement of 25 people including the Foreman.
- The plant processed a Nickel and Copper matte to produce a PGM concentrate, Nickel cathode, Copper cathode, Sodium sulphate and Cobalt.
- Responsible to the BMR Manager for the following: Safety; Production, Environment and loss prevention; Metallurgical accounting and production of monthly report; Organising shifts; Analysing plant performance and instituting corrective actions where necessary;
- Liaising with marketing on quality and quantity of finished products ready for dispatch and developing subordinates.
Achievements
- Played a key role in the operational phase by bringing refinery to 90% of design capacity with high quality Copper, Nickel and PGMs.
- Improved my people management skills.

5.JUNE 1997 – DECEMBER 1997
BHP World Minerals
Hartley Platinum Mine (Zimbabwe)
SENIOR METALLURGICAL ENGINEER
(Promotion)
Background
- After construction, came the cold and hot commissioning stage which lasted 4 months.
Responsibilities
- Providing process-engineering support to the plant operating staff.
- Supervising 2 Metallurgists and a Metallurgical Clerk
- Metallurgical accounting
Commissioning phase
- Lasted 4 months. Worked 12-hour shifts alongside Process Engineers. Divided into two groups.
- Tasked to commission the Platinum Base Metal Refinery with the listed main sections: Atmospheric leach, Pressure leach, Cobalt SX, Nickel and Copper electrowinning, Sulphur Removal Circuit, Formic Reducing leach and the Plant Utilities
Achievements
- Played a key role in the successful cold and hot commissioning of the refinery.
- Prepared the metallurgical accounting program that was used up to the closure of the operation.

6.AUGUST 1996 – MAY 1997
BHP World Minerals
Hartley Platinum Mine (Zimbabwe)
PLANT METALLURGIST
Background
- Joined BHP Hartley Platinum mine during the construction phase of the Base Metal Refinery.
- Construction was completed in August 1997.
- Beginning of January 1998 saw the Base Metal Refinery shifting from a commissioning to an operational phase.
Responsibilities
Construction phase
- Inspection of plant equipment against P&IDs.
- Signing off commissioning stages C1's to C4's.
- Preparation of the metallurgical accounting spreadsheet for the BMR (The spreadsheet was in use up to the closure of the operation).
- Writing work instructions and recruiting personnel.
- Training Shift Foremen and Senior Operators on Processes objectives, Chemistry and Control philosophy.
- Procurement of plant equipment such as pumps, plant laboratory equipment etc.
- Setting up the plant laboratory for process samples analysis.
- Training Shift Analysts and Samplers.
- Implementing plant modifications after carrying out hazop (hazard and operability) studies with other Engineers.
Achievements
- Played a key role in the construction phase of the refinery through inspections and signing off work completed by contractors.
- Set up laboratory benches, trained personnel to do acid/base titrations – these labs were useful and operational up to the end of the operation.
- Training of personnel on process chemistry, objectives and control philosophy – this helped reduce mishaps during commissioning.

7.JANUARY 1995 – JULY 1996
Zimbabwe Mining & Smelting Company
Zimbabwe
PLANT METALLURGIST
(Promotion)
Responsibilities
- Supervising two Junior Plant Metallurgists and a Metallurgical Clerk.
- Reporting to the Senior Plant Metallurgist.
- Carrying out daily metallurgical work on the plant.
- Metallurgical accounting.
- Producing daily and monthly reports.
- Involvement in projects.
- Commissioning of new plant and equipment – The New Spiral Plant.
- Trouble-shooting on plant problems and developing subordinates.
Achievements
- Played a key role in the successful commissioning of the spiral plant.
- Played a key role in a project aimed at determining the right blend and furnace operating conditions to produce a certain required grade of high carbon ferrochrome.

8.JANUARY 1994 – DECEMBER 1994
Zimbabwe Mining & Smelting Company
Zimbabwe
JUNIOR PLANT METALLURGIST
(Promotion)
Responsibilities
- Reporting to the Plant Metallurgist for the following.
- Carrying out daily metallurgical work on the plant.
- Assisting in projects and plant investigations.
Achievements
- Good grasp of metallurgical accounting.

9.JANUARY 1993 – DECEMBER 1993
Zimbabwe Mining & Smelting Company
Zimbabwe
GRADUATE METALLURGIST
Responsibilities
- Followed an I.M.M. (Institute of Mining and Metallurgy, U.K.) structured training programme.
Achievements
- Because of hard work and ability to produce technically sound reports – managed to complete program earlier than scheduled and was the first graduate in my group to be promoted to the next level.

Relevant Skills

Industry Related Courses
- Project Management E-learning Course (Anglo Platinum)
- Nosa Five star coaching course (Botswana Ash)
- Cost of quality (ZIMASCO)
- Process Capability (ZIMASCO)
- Managing Safety (BHP Hartley Platinum Mine)
- Advanced MS Excel (BHP Hartley Platinum Mine)
- Microsoft Office (Excel, PowerPoint, word) – BHP
- Situational Leadership (BHP Hartley Platinum Mine)
- Targeted Selection (BHP Hartley Platinum Mine)
- Hazard and Operability Study Techniques (ISHECON)
- Fundamentals of Risk Assessment (IRCA)
- Finance for Non-financial Managers (Maccauvlei)
- Chairing Disciplinary Enquiries (Botswana Ash)
- Firefighting course (Kasese Cobalt Company)

Memberships Professional Graduate [ProfGradIMMM] - Institute of Materials, Minerals and Mining (IOM3) U.K. Membership number (52658) - In process of being admitted as a Chartered Engineer.

Processes Knowledge and Skills
CoSX, ZnSX, Cu-EW, Ni-EW, Co-EW, Atmospheric Leach (Base Metals + PGMs), Bio-leach (Base Metals), Sulphide Pressure Leach (Base Metals + PGMs).
Process mass balance, Chairing production meetings, Chairing disciplinary enquiries, Organising and chairing hazard and operability studies, Project Management, Presentation of plant performance report at general meetings, Preparation of refinery budget, Representing production department in interdepartmental meetings, Managing multidisciplinary teams as Standby Manager

Computer Microsoft Office, MS Project, Honeywell

Language English, Shona and a little French.

Strengths
Leadership -
- As Senior Plant Metallurgist,showed leadership by giving direction on all process and technical related issues on the plant.
- BMR Superintendent (Jan '98 – Feb '00) – Led a team of just over 100 people.
- Hostel Chairman (3rd and 4th years at University – 1991 & 1992).
- Class Representative (1989 & 1990).
- Group Leader MBL Unisa (2006-2008): Led group to success, coming 6th in the top ten despite being a virtual group. All, but one successfully completed the program.
- Spearheaded cost-cutting initiatives which have helped the company survive the current economic downturn this far.
- Chairing production meetings/Hazard & operability meetings/disciplinary inquiries.

Communication
- Written several reports on plant investigations
- Made several presentations at company general meetings on the state of the plant
- Communication with consultants, suppliers by phone/e-mail
- Liaising with other departments on behalf of production department.
- A good reader – reviews all technical reports by Metallurgists before forwarding to senior management

Team building
As Senior Plant Metallurgist – brought together what was initially a group of Metallurgists into the technical team and led them into a strong and cohesive team achieving great results in the areas of plant troubleshooting, investigations and modifications.

Interests
Golf and travelling.

References
Available on request.

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