Trust Mbabvu

Ausmelt furnace and thus optimizing the process and improving safety
• Involved in the design and commissioning of matte treatment plant to produce cathode copper
• Designed and commissioned flocculent treatment system that reduced freshwater consumption by 23%
• Ensuring all Legal, Health, Safety and Environment standards and policies are always adhered to.
• Identifying and implementing continuous plant improvement initiatives.
• Providing detailed analyses of process control versus plant performance relationship.
• Developing control philosophies and implementing advanced process control for process stability and
optimal refractory campaign life
• Develop practical operating procedures, based on best industry practices and ensure compliance.
• Conduct detailed analysis and evaluation of existing metallurgical processes, identifying areas for
improvement and recommending appropriate solutions.
• Participate in cross-functional teams to drive root cause analysis, corrective actions and preventive
measures.
• Provide training and guidance to production teams on new processes, procedures and equipment to
ensure successful implementation and operation.
• Deriving measures for process optimization
• Checking and programming interlocks to ensure safety and process control.

• Design, program and commission automation of the flotation and filtration plants.
• Responsible for daily, weekly and monthly production reporting.
• Directly participate in the daily & weekly work activities of the processing plant, serving as technical
support to operations personnel to enhance performance
• Develop and manage scopes of work for metallurgical test work programs.
• Undertake and lead flotation test work, ore characterization and comminution improvement projects
• Conduct troubleshooting and detailed data analysis to identify root causes and corrective actions for
poor plant performance
• Ensuring all Legal, Health, Safety and Environment standards and policies are always adhered to.
• Drive small and large capital projects, reliability initiatives, and safety programs that ensure smooth
and efficient operations.
• Drive skills transfer and training, with the aim of increasing competencies and skillsets in junior staff
where possible, especially through interaction on projects.
• Developing operating methods and standard operating procedures related to process engineering tasks.
• Prospective solution to outstanding mid to long-term issues, including all areas of the plant.
• Plan and execute projects according to processing requirements, providing quality technical insights
on the results.
• Conduct quality audits and inspections to identify non-conformities and implement corrective actions.

• Managed production scheduling, plant shutdown coordination, and refractory performance
• Directed process optimization efforts to enhance efficiency, safety, and environmental compliance
• Supervised metallurgical teams, ensuring effective plant performance monitoring and control system
upgrades
• Monitor expenditure against budget
• Effective management of personnel
• Ensure all Health, Safety and Environment standards and polices are always adhered to

• Supervising and controlling the activities, standards of performance and training and development of
teams
• Plant optimization through the monitoring of key performance indicators.
• Championing the ISO 14001, OHSAS 18001, ISO 17025 and ISO 9001:2000 systems in the
metallurgical environment
• Running Pilot Plant and Laboratory test works for process investigation, improvement and setting
operating parameters.
• Design & commissioning of plant expansions.
• Co-ordinate efficient process operation operationally and technically in liaison with engineering
departments.
• Provide technical support and back up to the production department daily by monitoring process
efficiency, product quality and identifying process improvements to ensure budget recoveries are
achieved.
• Participates in project work aimed at process and product improvements and effectively co-ordinate
and conduct projects to meet required deadlines
• Maintaining and improving the metallurgical performance of the plant within established operational
parameters to ensure identified business plan targets are met with maximum efficiencies on budget.
• Minimize company risk exposure and liabilities by monitoring process-engineering activities to ensure
compliance with all statutory, regulatory and licensing requirements
• Daily and monthly Metallurgical Accounting

• Provide effective leadership, management and direction for process and control personnel to
continually optimize the process conditions and controls strategies
• Ensure that all site and government safety, health and environmental procedures and standards are
followed by plant personnel, and maintain close collaboration with the HS&E department to ensure
all workers are trained in safety and environmental matters
• Provide mentorship, guidance and coaching, leading to the growth and development of department
employees
• Provide input and assistance to the Process Plant Manager in preparing business plans, budgets, and
services to support delivery of the required results in production volumes, unit costs, and product
quality variation and reduce specific consumptions.
• Ensure efficient plant operations by directing and supervising teams to identify and correct deficiencies
continuously seek and promote opportunities for operational improvements, cost reduction and
technical innovation to maintain business profitability. Provide effective communication both within
and outside the department to ensure that all those affected have pertinent information to perform
their jobs effectively.
• Ensure that all operating procedures, training documents, drawings, etc. are continuously updated to
reflect current plant operation.
• Involved in R&D work on new processes as well as improvements to older ones
• DCS programming and faulty finding
• Co-ordinate efficient process operation operationally and technically in liaison with engineering
departments.
• Monitoring operation performance daily (tip pressure control, lance tip positioning, magnetite control
in slag, slag SiO2/Fe, matte grade control, and bath temperatures) and identifying areas for
improvement.
• Daily and monthly Metallurgical Accounting

• Governance of Smelter blueprint and manage risks of any changes through updates of drawings, SOPs,
functional descriptions and control philosophies.
• Provides adequate troubleshooting within Smelter Business Complex through measuring and
monitoring trend analysis - SCADA, process, financial, metal accounting.
• Develop Power BI models for data collection, profitability models, complete business cases and trade
off study documents for information sharing with the EXCO, Senior Management, Junior and
Leadership forums.
• Responsible to generate project user requirement specifications, process flow diagrams, financial cost
benefit analysis prior to project moving to stage gate 1.
• Conduct mass, energy, water and utility balances across Smelter.
• Evaluation of the Smelter metal balance from process order reviews, lockups.
• Conduct reviews of sampling and assaying through audits to understand risk of metal variability to
business.
• Commissioning and performance testing of new unit operations along with punch list activities and
training documentation and personnel.
• Lead investigations related to process, quality and governance incidents.
• Monitor and measure the cost of production for efficiency and continual improvement through best
practice and world class implementation.