Metallurgical Engineer Economist
Resume:
C* - INTERNAL
BERNARD NJELESANI
PROCESS OVERSEER
E: ****************@*****.***
L: www.linkedin.com/in/bernardnjelesanimscminerals PERSONAL PROFILE SUMMARY
Highly skilled and results-oriented Metallurgical Engineer with extensive experience in the continuous chemical/mineral process industry. Adept at optimizing operational efficiency, ensuring compliance with safety standards, and driving continuous improvement initiatives. Proven expertise includes process optimization, technical report writing, and fostering a culture of safety and collaboration. With a track record of success in process monitoring, problem-solving, and cross-functional teamwork, I am poised to make a significant contribution to the Mining Industry. EDUCATION AND TRAINING
Master of Science in Minerals and Energy Economics 2022 - 2024 Curtin University
Scholarships
Australia Awards Scholarship awardee 2022-2024
Bachelor of Engineering in Metallurgical Engineering 2007 - 2012 The Copperbelt University
KEY IMPACTS
High Pressure Leach Upgrade and Treatment Oct 2024 – Jan 2025 Successfully executed a $5.56 million capital project to enhance HPL plant performance, achieving over 98% copper recovery. Delivered a positive Net Present Value (NPV) of $4.1 million and an Internal Rate of Return
(IRR) of 16%, with a discounted payback period (DPBP) of just 7 months. Optimized plant operations to achieve full capacity, up from 66%, and increased copper transfer rates from solvent extraction to electrowinning from 130 t/day to 180 t/day.
Hydrometallurgical Rheology December 2024
Conducted an in-depth investigation of gangue acid-consuming (GAC) ores, focusing on high and low GAC types. Established a relationship between slurry density and rake torque, leading to the development of a predictive model for density control limits tailored to the ore type. This innovation increased thickener utilization from 80% to 95%, significantly enhancing process efficiency and operational performance. Optimizing HPL Leach Efficiency May 2024 – June 2024 Enhanced leach efficiency from 89% to 99% by optimizing oxygen utilization during the transition from chalcocite to chalcopyrite ore processing. Increased oxygen ratio from 0.65 to 0.90 to achieve complete oxidation, utilizing stoichiometric calculations aligned with plant data to refine operational parameters and maximize efficiency. Optimizing Oxygen Production and Consumption May 2024 – June 2024 Developed a control room model to balance oxygen production and consumption in the High-Pressure Leach (HPL) plant with a precision tolerance of 2 t/day. This optimization conserved 5 MW of power, significantly improving energy efficiency and operational control.
WORK EXPERIENCE AND RESPONSIBILITIES
Position Held : Process Overseer –High Pressure Leach, Oxygen and Acid Plant Jan 2024 - Present Company Name: Kansanshi Mine Plc, Solwezi, North-Western
• Currently directing and leading shift meetings to address safety concerns, communicate production figures, and discuss targets, continually enhancing effective communication.
• Paying attention to detail by meeting daily safety practices, health, and environmental Key Performance Indicators (KPI) in with local regulations.
• Executing strategic planning and preparations of budgets for the High Pressure Leach Plant to forecast realistic goals and plant copper input into overall circuit.
• Leverage technical efficiency by overseeing proper operation of equipment in accordance with operating instructions. Managed design, process control, technology and project for increased throughput and C2 - INTERNAL
treatment.
• Employing interpersonal and internal communications to facilitate effective dialogue among team members regarding direct reports.
• Leverage resource management skills by ensuring continual availability of tools and Personal Protective Equipment (PPE) for all employees.
• Demonstrating training and management skills by developing and executing evolving training schedules for production line employees based on skill matrices.
• Possessing documentation with clear writing style and process management skill by generating and reviewing Standard Operating Procedures (SOPs) in English to sustain operational standards.
• Portraying risk management skills by supervising and conducting Plant Task Observations in English to identify potential hazards and managing risks associated with processing of copper ore.
• Continually attaining performance management skills to assure achievement of daily production goals
(tonnages and recovery rates).
• Sustaining quality control standards throughout metallurgy production processes by paying attention to detail.
• Promoting and supervising a clean and safe work environment by implementing risk management measures, driving regulatory requirements and business objectives through best practices.
• Reporting defects and potential plant stoppages to personnel by applying strong communication skills and root cause analysis.
• Regularly attending weekly engineering planning meetings to coordinate operational activities, showcasing coordination and collaboration skills.
• Offering guidance and supervision during start-ups and shut-downs, particularly to shift controllers, continually demonstrating leadership skills.
• Offering problem-solving skills by delivering support to shift controllers and control room operators to improve plant performance during operational challenges.
• Showcasing leadership and communication skills by facilitating effective implementation of change management processes.
• Displaying leadership and accountability by enforcing discipline and adherence to working hours among subordinates and contractors translating into responsible operations.
• Continually enhancing effective communication and relationship building by conducting regular employee performance reviews and delivering constructive feedback.
• Demonstrating project management skills by coordinating monthly planned shut-down activities in collaboration with relevant stakeholders. Participating in team meetings and organizing capital projects. Position Held: Comminution Metallurgist - Concentrator Aug 2021 - Aug 2022 Company Name: Kansanshi Mine Plc, Solwezi, North-Western
• Identified and planned high quality execution of metallurgy comminution test based on mining plans work to optimize concentrator performance including metallurgical simulations and manage external service providers by testing new crusher liners.
• Prepared production of sectional, weekly, monthly and quarterly reports and use PI Vision for all operational trend analysis, Microsoft office such as excel and powerpoint, and evaluate concentrator data. Highly proficient in data analysis and reporting.
• Maintained HSE standards and ensured strict compliance within the Front-End Metallurgical team.
• Showcased continuous improvement and problem-solving skills by identifying potential improvements and implementing safe work procedures through inspection of plant condition monitoring and performance.
• Developed an equipment maintenance and production optimization skill by carrying out crusher liner wear management and control.
• Created statistical modelling skill by developing crusher performance data monitoring tools for right product size and carrying out plant trials and statistical analysis.
• Optimized supplier relationship management, contracts and negotiation processes by conducting all communication with crusher liner suppliers. Delivered profitable recommendations, supported by high- performance and productivity associated with selected liners.
• Created proposals, designs and technical specifications of capital projects specifically on the Jaw Crusher and secondary crushers to improve performance and stockpile product size.
• With ability to plan equipment maintenance and execution, coordinated mill shut-downs and carried out mill and cyclone inspections and advised any liner to change out.
• Gave process optimization of throughput capacity of crusher, mills and cyclones, driving production efficiency through effective leadership.
• Displayed proficient data management and database administration by sustaining a user-friendly, exhaustive and up-to-date database of all test-work. C2 - INTERNAL
• With process optimization and development skills in mineral processing, reviewed comminution metallurgical test-work, circuit survey procedures and create new procedures as required to support process development initiatives.
• Facilitated stakeholder management by managing interaction with Processing Operations teams to ensure high compliance to customer requirements.
• Showcased financial management and budgeting skill by contributing to annual technical section budget/forecasts.
• Applied cost management by supervising and reducing operational costs. Position Held : Operations Supervisor - Hydrometallurgy Aug 2017 - Aug 2021 Company Name: Kansanshi Mine Plc, Solwezi, North-Western
• Applied leadership and performance management by accomplishing production staff results and communicating job expectations. Planning, monitoring and appraising job results.
• Instituted process management and optimization by administering workflow by setting process variables, observing control points, equipment performance, and testing of experimental configurations deploying technical skills in process engineering.
• Continuous application of risk management and analysis by determining and assessing impact and risk assessment principles of low to medium risk changes on production system.
• Delivered data analysis and interpretation by determining and analysing production reports to ensure reduction in error process results.
• Exhibited problem solving and continuous improvement skill by implementing cost reduction measures and facilitating corrections to malfunctions within process control points.
• Delivered metallurgy expertise and communicated ideas into research by ensuring higher Leach Efficiency of above 95% acid soluble copper (%AsCu).
• Exercised resource management skill ensuring a complete production plan by scheduling and assigning personnel with specific responsibilities to accomplish production forecast.
• Delivered and electrochemical engineering and process management by ensuring higher current efficiencies above 80% in all tank houses and monitoring of impurity levels in cathode using laboratory assays.
• Brainstormed and negotiated improvement projects where one was scrubbing efficiency, improving regard for acceptable safety practices.
• By applying quality management skill, maximized quality service delivery by establishing and enforcing organization standards.
• Exhibited safety management skill by maintaining a safe and clean work environment. Educating and directing personnel on use of all control points, equipment and resources, maintaining compliance with established policies and safety procedures.
• By providing team building and collaboration, initiated and fostered a spirit of cooperation within and between departments.
• Developed labour relations management skill by maintaining work relationship with union by following terms of collective bargaining agreement to maintain company's compliance with laws and regulations.
• Exhibited succession planning and talent development by training and mentoring staff separately expeditiously developed into senior staff positions.
• Applied conflict resolution and problem-solving by resolving personnel problems by analysing data, investigating issues, identifying solutions, and instituting corrective strategies.
• Showcased people management and leadership by undertaking coaching, counselling, and disciplining employees, initiating coordination and enforcing systems, policies and procedures. Position Held: Control Room Operator - Hydrometallurgy Aug 2013 - Aug 2017 Company Name: Kansanshi Mine Plc, Solwezi, North-Western
• Gave problem solving and process optimization skill by examining, diagnosing and instituting recommendations during commissioning of hydrometallurgical plant.
• Delivered technical troubleshooting skill by making necessary adjustments on equipment units affecting speeds of chemical reactions, quality, and yields, preserving chemistry of process.
• By paying attention to detail, kept records of all process control instruments affecting variability in process and listened to warning signals in order to verify conformity of process conditions.
• Utilizing process automation, was able to oversee and operate chemical processes and systems of machines using Citect SCADA Control System to effect quality copper production and minimize losses.
• Applied process control engineering design by developing control loops participating in simulations and testing to enhance and control feed rate by mass flow balance from leach tanks to counter current decantation circuit.
• By deploying data analysis and performance evaluation skill, determined system performance indicators C2 - INTERNAL
and recommended improvement actions.
• Utilized expertise in data analysis and performance evaluation by identifying system performance indicators and proposed actionable improvement strategies based on findings.
• Provided cross-functional collaboration by resolving issues related to production process by utilizing cross-functional resources available.
• Utilizing communication and collaboration skills, managed to confer with technical and supervisory personnel to resolve conditions affecting safety, efficiency, and product quality.
• Applied emergency response and crisis management skill by regulating shut down equipment during emergency situations.
• Notified maintenance, other auxiliary personnel and provided technical support to correct equipment and machinery malfunction and to adjust accordingly as per protocol. REFEREES
Sylvester Mwape, Hydromet Manager, +260*********, *********.*****@****.*** Barnabas Nga'mbi, Concentrator Manager, +260*********, ********.******@****.*** Dickson Chirwa, HPL Superintendent, +260*********, *******.******@****.***
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