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

Produce unslaked lime using a rotary lime kiln 
SAQA US ID UNIT STANDARD TITLE
114264  Produce unslaked lime using a rotary lime kiln 
ORIGINATOR
SGB Pulp and Paper 
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY
-  
FIELD SUBFIELD
Field 06 - Manufacturing, Engineering and Technology Manufacturing and Assembly 
ABET BAND UNIT STANDARD TYPE PRE-2009 NQF LEVEL NQF LEVEL CREDITS
Undefined  Regular  Level 3  NQF Level 03  19 
REGISTRATION STATUS REGISTRATION START DATE REGISTRATION END DATE SAQA DECISION NUMBER
Passed the End Date -
Status was "Registered" 		 2004-02-11  2007-02-11  SAQA 2152/04 
LAST DATE FOR ENROLMENT LAST DATE FOR ACHIEVEMENT
2008-02-11   2011-02-11  

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 replaces: 
US ID Unit Standard Title Pre-2009 NQF Level NQF Level Credits Replacement Status

This unit standard is replaced by: 
US ID Unit Standard Title Pre-2009 NQF Level NQF Level Credits Replacement Status
246639  Produce unslaked lime using a rotary lime kiln  Level 3  NQF Level 03  10   
256300  Monitor and control the unslaked lime process using a rotary lime kiln  Level 3  NQF Level 03  10   

PURPOSE OF THE UNIT STANDARD 
Qualifying learners will be able to produce unslaked lime using a rotary lime kiln by operating, monitoring and controlling the process whilst adhering to Safety, Health, Environmental and Quality requirements. They also understand the process principles/fundamentals of producing unslaked lime using a rotary lime kiln. 

LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
Learners attempting this unit standard are required to read, understand and interpret operating manuals which are of a technical nature. It is therefore required that they have achieved NQF level 2 or equivalent accreditation. 

UNIT STANDARD RANGE 
This unit standard covers the setting up, operating and storing of unslaked lime using a rotary lime kiln. 

Specific Outcomes and Assessment Criteria: 

SPECIFIC OUTCOME 1 
Qualifying learners are able to discuss & explain the fundamental principles of producing unslaked. 
OUTCOME NOTES 
Qualifying learners are able to discuss and explain the fundamental principles of producing unslaked lime using a rotary lime kiln. 

ASSESSMENT CRITERIA 

ASSESSMENT CRITERION 1 
1. The purpose of the process as well as the relationship to the supplier and customer`s processes is discussed and explained. 

ASSESSMENT CRITERION 2 
2. All items of equipment are identified and their functions are discussed and explained. 

ASSESSMENT CRITERION 3 
3. The effects of the process variables on the properties of burnt lime are discussed and explained. 
ASSESSMENT CRITERION RANGE 
Process Variables:
Temperature, rotary speed, gas flow, lime mud flow, lime mud solids, air flow, pressure, oxygen percentage.

Properties:
Slaking time, particle size, calcium carbonate.
 

ASSESSMENT CRITERION 4 
4. The structures and composition of the raw material in terms of unslaked lime are discussed and explained. 

ASSESSMENT CRITERION 5 
5. Lime burning principles in terms of chemical reactions, temperatures, production rates are discussed and explained. 

ASSESSMENT CRITERION 6 
6. Lime kiln terminology, relating to lime quality in terms of slaking time, residual oxides and calcium carbonate percentages, is discussed and explained. 

ASSESSMENT CRITERION 7 
7. Standard Operating Procedures for the lime kilns including parameters are understood. 

ASSESSMENT CRITERION 8 
8. The sequence of steps for the operating, monitoring and controlling of the process as per Standard Operating Procedures is discussed and explained. 

ASSESSMENT CRITERION 9 
9. All quality specifics are discussed and explained in detail. 

SPECIFIC OUTCOME 2 
The learner will have learned to engage in the operational processes and procedures to produce. 
OUTCOME NOTES 
The learner will have learned to engage in the operational processes and procedures to produce unslaked lime using a rotary lime kiln. 

ASSESSMENT CRITERIA 

ASSESSMENT CRITERION 1 
1. The pre-checks are carried out and the process is started up. 

ASSESSMENT CRITERION 2 
2. Process variables are set to customer or product requirements. 
ASSESSMENT CRITERION RANGE 
Process Variables:
Rotary speed, temperature.
 

ASSESSMENT CRITERION 3 
3. The process is shut down. 

ASSESSMENT CRITERION 4 
4. The emergency shut down procedures are explained and simulated or demonstrated. 

ASSESSMENT CRITERION 5 
5. Plant is prepared for maintenance. 
ASSESSMENT CRITERION RANGE 
Electrical, instrumentation, process and mechanical isolations.
 

SPECIFIC OUTCOME 3 
The learner will have learned to monitor and control the process of producing unslaked lime. 
OUTCOME NOTES 
The learner will have learned to monitor and control the process of producing unslaked lime using a rotary lime kiln. 

ASSESSMENT CRITERIA 

ASSESSMENT CRITERION 1 
1. The process variables are monitored and recorded. 

ASSESSMENT CRITERION 2 
2. Process variables are evaluated and deviations are brought into control. 
ASSESSMENT CRITERION RANGE 
Includes gas flows, mud flows and solids content, process flows and production rate.
 

ASSESSMENT CRITERION 3 
3. Product variations are evaluated and deviations are brought into control. 
ASSESSMENT CRITERION RANGE 
Includes slaking time, particle size and calcium carbonate percentage.
 

SPECIFIC OUTCOME 4 
Qualifying learners are able to adhere to Safety, Health, and Environmental requirements. 
OUTCOME NOTES 
Qualifying learners are able to adhere to Safety, Health, and Environmental requirements including the requirements of Standard Operating Procedures. 

ASSESSMENT CRITERIA 

ASSESSMENT CRITERION 1 
1. The hazards and risks associated with the process are identified and relevant prescribed precautions are discussed and explained or demonstrated. 

ASSESSMENT CRITERION 2 
2. Environmental hazards are identified and the relevant precautions to be taken are discussed and explained according to plant environmental procedures. 

ASSESSMENT CRITERION 3 
3. The consequences caused by gaseous emissions are discussed and explained. 

ASSESSMENT CRITERION 4 
4. Company safety procedures and housekeeping standards are understood and adhered to. 


UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
Anyone assessing a learner against this unit standard must be registered as an assessor with the relevant ETQA.

Any institution offering learning that will enable achievement of this unit standard must be accredited as a provider through the relevant ETQA by SAQA.

Moderation of assessment will be overseen by the relevant ETQA according to the moderation guidelines in the relevant qualification and the agreed ETQA procedures. 

UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE 
Things the learner knows and can explain:

Names, Functions and Locations of:
  • All items of installed equipment
  • Raw material
  • Intermediate product/s
  • Finished product/s

    Description, properties and characteristics of:
  • Raw materials
  • Product/s
  • Process equipment
  • Auxiliary equipment
  • Process system/s

    The Purpose of the:
  • Process, in terms of product/s, efficiencies and quality

    Causes, effects and implications of:
  • Process variables
  • Raw material variables (suppliers)
  • Product variables (customers)
  • Hazards
  • Not complying with safety standards
  • Not complying with standard operating procedures
  • Not complying with quality specifications

    Procedures and techniques of:
  • Standard Operating for the starting up, monitoring, controlling and shutting down of the process
  • Recording and reporting data

    Regulations, legislation, agreements and policies related to:
  • Occupational Health and Safety Act
  • Environmental issues
  • Housekeeping
  • Company Safety Procedures
  • Standard Operating procedures
  • Quality specifications
  • Relevant mensuration and units 
    		•

    UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
    Identify and solve problems:
  • Evaluate variables and bring deviations under control.
  • Identify hazards and risks associated with the process and describe relevant precautions. 
    		•

    UNIT STANDARD CCFO ORGANISING 
    Organise and manage self and activities:
  • Work to achieve consistent results required by the process/ customer.
  • Participate in life-long learning. 
    		•

    UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organize and critically evaluate information:
  • Monitor and record process variables.
  • Bring process deviations under control. 
    		•

    UNIT STANDARD CCFO COMMUNICATING 
    Communicate effectively:
  • Record process variables and actions taken to rectify.
  • Respond to questions and requests for additional information.
  • Liaise with relevant operational support units.
  • Report incidents and conditions. 
    		•

    UNIT STANDARD CCFO SCIENCE 
    Use science and technology effectively and critically, showing responsibility towards the environment and health of others:
  • Carry out pre-checks on process and equipment.
  • Monitor the process.
  • Bring process variables into control. 
    		•

    UNIT STANDARD CCFO DEMONSTRATING 
    Demonstrate an understanding of the world as a set of related systems by recognising that problem-solving contexts do not exist in isolation by:
  • Explain the purpose of the process as well as the relationship to the supplier and customer`s processes. 
    		•

    UNIT STANDARD ASSESSOR CRITERIA 
    N/A 

    UNIT STANDARD NOTES 
    This unit standard will be replaced by unit standard 256300, which is "Monitor and control the unslaked lime process using a rotary lime kiln", Level 3, 10 credits, as soon as 256300 is registered.

    This unit standard has been replaced by unit standard 246639, which is "Produce unslaked lime using a rotary lime kiln", Level 3, 10 credits.

    This unit standard replaces unit standard 13609, "Produce unslaked lime using a rotary lime kiln", Level 3, 20 credits.

    Definition:

    Workplace procedures refer to instructions on policies and procedures which are formally documented and are available for reference. Examples include: standard operating procedures, workplace instructions, specifications, manuals, and manufacturers` information. 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Elective  48645   Further Education and Training Certificate: Pulp and Paper Chemical Recovery  Level 4  NQF Level 04  Passed the End Date -
    Status was "Registered"     		 2007-02-11  Was FPMSETA until Last Date for Achievement 


    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.
     
    1. SAPPI SAICCOR 


    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.