Summary
Overview
Work History
Education
Skills
Certification
Major Highlights
Core Competences
References
Timeline
Generic

James Kasonteka

Port Pirie,South Australia

Summary

Highly technical Metallurgist professional with excellent technical expertise, and analytical and problem-solving skills in mining, Process, Smelting and refining plants (Hydro & Pyro-Metallurgy) over 10 years. Skilled in process optimization in a safe, highly efficient and sustainable manner while executing and overseeing strategic metallurgical and operational projects in a cost and safe effective manner to meet organizational goals. Led the design of furnace refractory heating burners which saved $250,000 and 35% Diesel savings in costs annually, and earned the company the most Environmental compliance through effective maximum SO2 and dust capture emissions. Proficient Metallurgist offering 10 years of experience in driving continuous process improvement and implementation in mining and smelting industries. Excellent leadership, project management and program development skills. Prepared to apply knowledge and abilities to challenging new role.

Overview

8
8
years of professional experience
1
1
Certification

Work History

Senior Metallurgist Technical Projects

Nyrstar
Port Pirie, South Australia
01.2023 - Current
  • Identify projects to meet both short and long-term goals.
  • Provide technical advice, support and strategic process direction to the operations teams.
  • Champion safe, efficient and cost-effective production, guiding the Metallurgy team and Production Operators to ensure that optimum performance standards are achieved and that technical integrity is maintained.
  • Provide proactive innovation and problem-solving solutions to the identified plant issues.
  • Guide and collaborate with the operations team to optimize performance.
  • Develop and maintain quality measurement and reporting systems including production planning, metallurgical accounting and reporting, production forecasting and physicals budget preparation.
  • Identify and implement continuous improvement projects and drive value creation
  • Contribute to the operation meeting licence, legislation and internal limits by ensuring that all technical advice and direction provided address safety and environment requirements.
  • Help in training and developing the metallurgists and operations teams

ASSISTANT SUPERINTENDENT-TECHNICAL SMELTER AND SULPURIC ACID PLANT 1850T/D

Konkola Copper Mines Plc
03.2020 - Current
  • Evaluated toll treatment efficiencies and optimized the operations to attain Copper and Cobalt recoveries from 98.2 to 98.6% and 60 to 60.5% respectively
  • Successfully led and managed large projects, and provided timely and quality results
  • Championed sustainable fuel furnace consumption project at the primary furnace from 17,000kg/day to 9000kg/day by optimizing chalcopyrite on the blend from 20 to 25%
  • This saw economic benefit as well as prolonging the life line of furnace refractories from wear
  • Provided technical advice and consultative services to the operations team on increasing acid production while operating at lower feedrates i.e
  • Reducing effluent generation (from 140Mt to <100Mt), optimizing stack (from 1500ppm to 980ppm) performance and modelling feed input
  • Prolonged Converter catalyst life by 3years through sustained operations of the Wet ESPs, Dry ESPs and Gas cooling plant (GCP)
  • Identify areas of technical improvements and provide solutions to operational problems within the smelter
  • Collaborate with engineering and operations teams in carrying out project feasibility studies, executing and commissioning stages as per Gantt chart
  • Prepared cost benefit analysis or business case studies for the identified technical projects
  • Utilize Microsoft Projects - Gantt chart in planning, managing and tracking all project activities from initiation to completion stage
  • Participates in a technical committee in providing technical expertise and consultancies to the operational teams with a focus on executing identified projects to meet organizational goals
  • Apply quality management skills in ensuring 100% product compliance to the standard i.e
  • Copper anodes, Cobalt Alloy, Sulfuric acid, Oxygen and process water
  • Identify and evaluate potential project operational improvements that can debottleneck the plant operations
  • Identify and implement process improvement projects within a required budget, established timeframes and to agreed expectations (quality)
  • Successfully managed and championed technical studies to provide robust, applied and problem technical solutions to the operations team
  • Successfully conducted a research study on reducing Bismuth content in the anodes from 380ppm to >280ppm with the aim of increasing cathode quality at fire refining
  • Achieved and sustained the safest, most economic and environmentally operations around the Smelter equipment by providing proactive technical solutions and advices to the operations team
  • Designed safe and environmental aligned standard operating procedures that led to process improvements and key technical parameters compliance to the design
  • Integrate overall business vision that gives the best financial result for the operations
  • Conduct Technical training and mentorship to the operations team aiming at attaining organizational goals
  • Prepare technical reports and presentations
  • Designed process advisor of primary feed input that helped to achieved 97% of slag chemistry desired
  • Achieved the highest copper production numbers in 2021 since the commissioning of the Smelter which saw huge revenue to the company
  • Responsible for designing and carrying out of Pilot trials for strategic projects.

SENIOR PLANT METALLURGIST

Konkola Copper Mines Plc
06.2018 - 04.2020
  • Optimized coke matrix at the arc electric furnace to achieve %Cu in the slag cleaning furnace between 4 to 6% and that in the discard slag of below 0.4%
  • Optimized electrode management at the arc electric furnace to safeguard the refractory lining as well as effective blister and slag separation i.e
  • Cu in slag of 5.5% on average against design of <6%
  • Successfully modified the slag chemistry at Cobalt Recovery Furnace (CRF) modifying the melting point of cobalt i.e
  • 1320oC instead of 1490oC
  • This led to economic and operational benefits
  • Conducted a study on prolonging the life line of disposable cartridge filters while led to a saving of $250,000 annually
  • Revised sustained operating protocols of the polished mixed beds (ion exchange method) which led to prolonged period of operations from 3days to 5days thereby saving $18,000 on treatment chemical costs
  • Guided a metallurgical team on protecting the reverse osmosis (RO) Membranes from premature tear and wear by optimizing the feed water and chemicals used for cleaning in place (CIP)
  • Monitored, controlled and achieved 100% performance of the cooling towers which prevented heat losses, fouling effect and rusting of the equipment
  • Ensuring that all controlled parameters across the Smelter and technically controlled as per design
  • Implement and Coordinate Environmental Management System (EMS), Quality Management System (QMS) and Safety Management system (OHSAS)
  • Counter checking for validity and reliability of Lab results (Assay)
  • Help in Shut down planning for critical works
  • Achieved 85t/hr of anode casting rate against the design of 80t/hr which led to improved production planning thereby meeting the daily casting targets
  • Minimized total refining time from 8hrs to 6hrs thereby gaining 20% on fuel costs as well as improved production planning.

SHIFT CONTROLLER

Konkola Copper Mines Plc
09.2016 - 06.2018
  • Warranted and achieved 100% compliance of the Shift regarding daily plan and targets
  • Ensured maximum adhere to all relevant requirements, policies, procedures and legal regulation pertaining to health, safety, environment and quality, human resource, finance and any other regulations as required by the company
  • Carried out successful risk assessments for critical tasks with free incident job executions
  • Issued correct work permits concerning various jobs to be executed
  • Tracked and executed preventive maintenance plan for all the equipment
  • Monitor 100% compliance of critical parameters and provide corrective actions for deviations
  • Conducted process controls through assay results interpretation (feedback and feedforward reactions)
  • Achieved 100% blister and slag tapping as per plan
  • Prepared operational and safety shift reports.

Education

Masters Of Science In | Environmental Engineering, Monitoring And Management -

Copperbelt University

Bachelor Degree | Chemical Engineering -

Copperbelt University

Skills

  • Value-add decision making
  • Mentorship & Development
  • Innovative and creative skills
  • Leadership and Management
  • Teamwork
  • Business awareness skills
  • Technical presentations skills
  • Microsoft Excel
  • Project Management skills
  • Problem-solving skills
  • Research Skills
  • Excellent communication skills
  • Business case development skills
  • The ability to focus on results
  • Planning and coordination skills

Certification

  • Quality Management System- ISO 9001: 2015 ALISON UK
  • Principles of Occupational Health and Safety Management Systems-ISO 45001:2018 ALISON UK
  • Environmental Management System-ISO 14001:2015 ALISON UK
  • ISO Management System Audit Techniques and Best Practices ALISON UK
  • Engineering Institute of Zambia
  • The Engineering Registration Board (EngRB)
  • First Aid Certificate

Major Highlights

  • Pioneered Manufacture of Castable which saved $150,000 in costs monthly and averted potential plant stops.
  • Modified surface water treatment plant to ground water treatment plant which promoted 100% plant availability on account of adequate process water supply.
  • Designed steam heater at the Oxygen Plant for Temperature Swing Adsorbers (TSA) as an economic replacement of Electric Heater Banks which saved the company $150 hourly from power costs.
  • Modified Copper standard input for Outokumpu Direct to Blister (Flash Smelting Furnace) which saw a rise in copper feed by 5%.
  • Optimized primary and secondary slag chemistry with the aim of prolonging furnace campaign life by 2 years.
  • Optimized the coating of the furnaces by improving magnetite (Fe3O4) in the slag from 20 to 25%.
  • Managed to leach generated dust from the primary furnace thereby improving on the environmental control and compliance as well as adding economic value to the Tailing Leach Plant.

Core Competences

  • Value-add decision making
  • Mentorship & Development
  • Innovative and creative skills
  • Leadership and Management
  • Teamwork
  • Business awareness skills
  • Technical presentations skills
  • Microsoft Excel
  • Project Management skills
  • Problem-solving skills
  • Research Skills
  • Excellent communication skills
  • Business case development skills
  • The ability to focus on results
  • Planning and coordination skills

References

  • Mr. Kaniki Brian, Technical Manager, briankkaniki@gmail.com, +260967/977-486764
  • Mr. Duncan Balasi, Assistant Supt-Concentrator Konkola, Konkola Copper Mines Plc, +260956504103/+260969927660, duncan.balasi@kcm.co.zm
  • Dr. Elisha Ncube, Head of department, Copperbelt University, +260977662278/+260960970242, enncube@yahoo.com

Timeline

Senior Metallurgist Technical Projects

Nyrstar
01.2023 - Current

ASSISTANT SUPERINTENDENT-TECHNICAL SMELTER AND SULPURIC ACID PLANT 1850T/D

Konkola Copper Mines Plc
03.2020 - Current

SENIOR PLANT METALLURGIST

Konkola Copper Mines Plc
06.2018 - 04.2020

SHIFT CONTROLLER

Konkola Copper Mines Plc
09.2016 - 06.2018

Masters Of Science In | Environmental Engineering, Monitoring And Management -

Copperbelt University

Bachelor Degree | Chemical Engineering -

Copperbelt University

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James Kasonteka