Metallurgical Plant Material Crushing Operations Training

Learning Outcomes

• Demonstrate the ability to prepare and start up crushing equipment according to standard operating procedures.
• Operate crushing equipment to reduce material size while monitoring process parameters and making adjustments as needed.
• Apply safety and environmental procedures during crushing operations to prevent incidents and minimize impact.
• Monitor and control the quality of crushed material to meet specified product requirements.
• Perform routine maintenance and troubleshoot common equipment faults to ensure continuous operation.
• Complete required documentation and report on crushing process performance and deviations.

Target Audience

This course is designed for plant operators, process controllers, and technicians working in metallurgical plants who are responsible for material crushing operations.

Prerequisites

None — open enrollment.

Course Outline

Practicals

Overview

Practical sessions are integral to this course, allowing learners to apply theoretical knowledge in a controlled environment. Learners will operate crushers, adjust settings, perform maintenance tasks, and simulate troubleshooting scenarios under supervision. These hands-on activities ensure competence in safe and efficient crushing operations.

Practical Activities

• Crusher Pre-Start and Start-Up Procedures — Learners perform a pre-start inspection on a jaw crusher and a cone crusher, then execute the correct start-up sequence, including communication with the control room. (3h)
• Adjusting Crusher Settings and Monitoring Performance — Learners adjust the closed side setting (CSS) on a cone crusher and monitor changes in power draw and product size. They record data and interpret trends. (4h)
• Routine Maintenance and Lubrication — Learners perform routine maintenance tasks including greasing bearings, checking oil levels, inspecting liners, and replacing a worn liner segment under supervision. (4h)
• Troubleshooting and Emergency Response Simulation — In a simulated environment, learners respond to common issues such as a crusher jam, tramp metal event, and power failure. They demonstrate correct shutdown procedures and isolation. (3h)
• Integrated Crushing Circuit Operation — Learners operate a small-scale crushing circuit, coordinating feeder, crusher, and conveyor settings to achieve a target product size and throughput. (2h)

Summatives

Each delegate is assessed continuously throughout the course via daily exercises, scored practical assignments, and a final summative test at the end.

Practical Assignments — 30%

Practical assignments are observed and scored against a rubric during the practical sessions. Each delegate's practical mark is averaged into a single 100% score and contributes 30% to the final total.

Daily Exercises — 20%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 20% to the final total.

Final Test — 50%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 50% to the overall mark.

Final Total

Component	Out of	Weight
Practical Assignments (rubric-scored)	100%	30%
Daily Average (multiple choice)	100%	20%
Final Test (multi-answer multiple choice)	100%	50%
Final Total	—	100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

How it works

• Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
• Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
• You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
• If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.

Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates	Discount
5	3% off
10	6% off
15	9% off
20	12% off
25	15% off
30	18% off
50	30% off
75	35% off
100	40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.