Control Room Operator (Gyratory Crusher)

Control Room Operator (Gyratory Crusher)

Department

Processing / Crushing & Milling

Job Purpose

To safely and efficiently monitor, control, and optimize the operation of the primary gyratory crusher and associated material-handling systems from the control room. The operator ensures consistent ore feed quality, equipment protection, minimal downtime, and compliance with metallurgical requirements to support zinc production targets.

Key Responsibilities

• Crusher & Plant Monitoring
• Operate the primary gyratory crusher, feeders, conveyors, chutes, scalping screens, and dust suppression systems from the control room.
• Monitor equipment performance using SCADA/DCS systems.
• Adjust feed rates to ensure optimal crusher throughput and product size.
• Identify and respond to process upsets (blockages, overloads, low level, tramp metal alarms).

Safety & Compliance

• Follow mine site safety regulations, lock-out/tag-out (LOTO), confined space rules, and emergency procedures.
• Report safety concerns and participate in daily safety briefings.
• Ensure dust control, noise levels, and environmental compliance are maintained.

Equipment Protection & Troubleshooting

• Monitor lubrication systems, hydraulic pressures, motor loads, bearing temperatures, and vibration indicators.
• Detect abnormal conditions and coordinate immediate corrective action with field operators.
• Respond to crusher trips, alarms, and interlocks to safely restart equipment.

Coordination & Communication

Communicate with:

• Field attendants
• Maintenance teams
• Control room process operators (downstream)
• Mining dispatch (ore delivery)

• Provide clear instructions during start-ups, shutdowns, and maintenance interventions.

Quality & Production Control

• Maintain consistent ore feed according to metallurgical specifications for zinc beneficiation.
• Monitor ore type changes and adjust operational parameters accordingly.
• Record hourly production, downtime events, and shift log entries.

Housekeeping & Documentation

• Maintain accurate shift reports, production logs, and incident records.
• Ensure the control room is clean, organized, and secure.
• Assist with risk assessments, SOP reviews, and continuous improvement initiatives.

Required Skills & Competencies

Technical Skills

Operation of primary crushing circuits (preferably gyratory crushers such as Metso, Sandvik, FLSmidth).

Familiarity with:

• SCADA / DCS systems
• Conveyor systems and feeders
• Ore sizing and primary fragmentation principles
• Basic understanding of mechanical and electrical equipment.

Qualifications & Experience

• Minimum Requirements
• Grade 12 (Matric) or equivalent.
• At least 2–5 years' experience in a crushing plant or mineral processing environment.
• Previous experience with gyratory crushers is highly advantageous.
• Computer literacy and familiarity with plant control systems.

Preferred

• National Certificate in Mineral Processing or similar.
• Experience on a zinc, lead, or base metal mine.
• Knowledge of Mine Health & Safety Act (MHSA) requirements.

Physical & Environmental Conditions

• Work primarily in a control room with periodic inspections in the plant.
• Exposure to noise, dust, and vibration when outside the control room.
• Must be able to climb stairs and handle emergency response duties if needed.

Key Performance Indicators (KPIs)

• Crusher uptime percentage.
• Throughput and product size consistency.
• Safety compliance with zero incidents.
• Accurate and timely reporting.
• Effective communication with field teams.