1. 1 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Demonstrate understanding of the water treatment and effluent treatment processes in the pulp and paper industry

2. 2 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 ModulesTopics P&P4EL Water treatment process BE407Understanding the water treatment process Total Notional Hours Notional Hours Demonstrate understanding of the water treatment and effluent treatment processes in the pulp and paper industry BE407Understanding the process feedstock and final products BE407Understanding variations in the process BE407 Apply sampling practices 18 8 4 6 36 P&P4EL Quality

3. 3 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development BE407 Understanding the water treatment process US: U0005Understand the process and variables in wet end operations in the pulp and paper industry Are able to explain the basic flows in a generic water treatment process Understand the purpose of the water treatment process and how it fits into the total pulp and paper process Are able to identify each of the major pieces of equipment in a generic water treatment process Understand the basic operating principles / chemical reactions of the flocculants, coagulants, disinfectants, water softeners, air, steam and pH control chemicals used in the treatment process Understand the fundamental operating principles associated with the water treatment process

4. 4 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BE407 The water treatment process Learning ActivitiesTopic assessment criteriaAssignment Description WHATWHAT HOW Notional Hours 18 Collect Information Use Multi media Self Study Plant investigation Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Sketch Case studies Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a questionnaire The assessor will observe and confirm that learners: Understand the purpose of the water treatment process and how it fits into the total pulp and paper process Are able to identify each of the major pieces of equipment in a water treatment process Are able to explain the basic flows in a water treatment process Understand the fundamental operating principles associated with the water treatment process Understand the basic properties and characteristics of the flocculants, coagulants, disinfectants, water softeners, air, steam and pH control chemicals used in the treatment process 1.Learners are provided with relevant plant and equipment information / manuals 2.Inspect the plant and determine the flow of material through the plant 3.Draw a block diagram to show where water treatment fits into the papermaking process, specifically noting sources of raw water and consumers of treated water (indicate rough quantities) 4.Draw a basic layout sketch of this area and its main networks 5.In a discussion with a plant specialist, identify: the purpose of the water treatment plant the plant and equipment used in the process, the fundamental operating principles of each piece of equipment 6.Complete a questionnaire to indicate findings Individual or group training. Do self study to develop key plant operation questions. Answers are obtained by discussions with production experts and plant investigation.

5. 5 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development Understand the water specifications for water going to brown and white product processes and reasons for each quality standard BE407 Understanding the process feedstock and final products Know the suppliers of feed water and the customers for the treated water US: U0005Understand the process and variables in wet end operations in the pulp and paper industry Know the typical properties and composition of treated water and feed water from different sources Be able to construct a spreadsheet with throughputs, specifications, typical results and reasons for each specification Be able to carry out quality checks on the feed water and treated water

6. 6 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BE407 The process feedstock and products Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Know the suppliers of feed water and the customers for the treated water Understand the water specifications for water going to brown and white product processes and reasons for each quality standard Know the typical properties and composition of treated water and feed water from different sources Are able to carry out quality checks on the feed water and treated water Are able to construct a spreadsheet with throughputs, specifications, typical results and reasons for each specification Assignment Description WHATWHAT HOW Notional Hours 8 Collect Information Use Multi media Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Educational games Case studies Tabulate Develop recommendations Execute, test and evaluate Job assignment Make presentation Draft a report Plant investigation Complete documents Complete a questionnaire Individual or group training. Obtain basic water and source information by discussions with production experts. A spreadsheet showing required and typical feed water and treated water qualities is drawn up. 1.Learners are supplied with information on water quality 2.Have a facilitated group discussion to determine by whom the feed water is supplied and who the customers of the treated water are 3.Learners use inputs from production experts to produce a spreadsheet with the following information feed water quality requirements treated water quality requirements for white and brown products and other applications reasons for each requirement typical, actual qualities impact of deviations from specification on downstream customers 2.An introduction is drafted to accompany results

7. 7 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development Know the effect of variations and deviations on the process and treated water BE407 Understanding variations in the process Understand what process deviations could occur in the process Be able to complete all log sheets Understand how a variations in the properties of the feed water will impact on the process Understand what feed water variations could occur in the process US: U0005Understand the process and variables in wet end operations in the pulp and paper industry

8. 8 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BE407 Variations in the processes Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Are able to complete all log sheets. Understand what feed water variations could occur in the process Understand what process deviations could occur in the process Know the effect of variations and deviations on the process and treated water Assignment Description WHATWHAT HOW 1.Learners are supplied with log sheets and assisted to complete them with the help of a production specialist 2.Individually list the feed water and process variations that could occur and the effect each type of variation could have on the final product and / or in downstream processes or products 3.In a facilitated discussion at the site, identify and list the effect each type of deviation could have on the final product and / or in downstream processes or products 4.Tabulate all variations and deviations, their effects and the broad rectification action required and compile the information into a report Notional Hours 4 Individual or group training. Use the information on the feedstock obtained earlier to list quality variations. A facilitated discussion to identify possible process deviations and the downstream effects. Collect Information Use Multi media Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Educational games Case studies List / Tabulate Develop recommendations Execute, test and evaluate Job assignment Make presentation Draft a report Plant investigation Complete documents Complete a questionnaire

9. 9 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development BE407 Apply sampling practices Understand the principles of sampling used in the water treatment process Be able to interpret the test results in terms of the impact on the process and customers Be able to construct a basic spreadsheet for water sources and sample results Be able to do sampling according to plant standards US: U0005Understand the process and variables in wet end operations in the pulp and paper industry

10. 10 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BE407 Apply sampling practices Collect Information Use Multi media Self Study Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Case studies List / tabulate Develop recommendations Execute, test and evaluate Make presentation Complete documents Draft a report Complete a test Learning ActivitiesTopic assessment criteriaAssignment Description WHATWHAT HOW Notional Hours 6 Plant investigation Educational games The assessor will observe and confirm that learners: Understand the principles of sampling used in the water treatment process Are able to do sampling according to plant standards Are able to construct a basic spreadsheet for different water sources and sample results Are able to interpret the test results in terms of the impact on the process and customers Learners are given a short lecture on the statistical basis of sampling practice. Sampling is demonstrated and then done under supervision. A spreadsheet showing required and typical raw water and treated water qualities is drawn up. 1.Learners are given a lecture on the statistical basis of sampling practice and tied into the sampling practice in the water treatment area. 2.A typical sampling procedure is outlined and a simple checklist compiled 3.Learners view a demonstration of sampling and take a full range of water samples under supervision 4.The results of samples are compared to water specifications and typical values previously obtained 5.A short report outlines findings Expert demonstration Job assignment

11. 11 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Modules Topics P&P4EL Effluent treatment process BE407Understanding the effluent treatment process Total Notional Hours Demonstrate understanding of the water treatment and effluent treatment processes in the pulp and paper industry P&P4EL By-products BE407By-products recovered in the effluent treatment process BE407Applying SHE in water and effluent treatment P&P4EL SHE BE407Understanding the process feedstock and final products BE407Understanding variations in the process BE407 Apply sampling practices P&P4EL Quality 20 8 6 16 8 64 Notional Hours

12. 12 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development BE407 Understanding the effluent treatment process Be able to explain the basic flows in the process Understand the purpose of the effluent treatment process and how it fits into the total pulp and paper process Be able to identify each of the major pieces of equipment Understand the basic properties and characteristics of all chemicals used in the process Understand the fundamental operating principles associated with the process Understand the basic scientific principles of filtration, flocculation and coagulation and clarification how these are applied in the processes US: U0005Understand the process and variables in wet end operations in the pulp and paper industry

13. 13 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BE407 Understanding the effluent treatment process Collect Information Use Multi media Self Study Plant investigation Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Sketch Summarise Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a questionnaire Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Understand the purpose of the effluent treatment process and how it fits into the total pulp and paper process Are able to identify each of the major pieces of equipment Are able to explain the basic flows in the process (chemical treatment, clarification, maturation, aeration, naturation) Understand the fundamental operating principles associated with the process Understand the basic properties and characteristics of all chemicals used in the process Understand the basic scientific principles of filtration, flocculation and coagulation and clarification and how these are applied in the processes Assignment Description WHATWHAT HOW 1.Learners are provided with relevant plant and equipment information / manuals 2.Inspect the plant and determine the flow of effluent through the plant 3.Draw a block diagram to show where the effluent treatment process fits into the papermaking process, specifically noting sources of effluent and treated effluent recipients (indicate rough quantities) 4.Draw a basic layout sketch of this area 5.In a discussion with a effluent treatment specialist, identify: the purpose of the process the different equipment used in the process, and the fundamental operating principles of each treatment step 6.Complete questionnaire to indicate findings Notional Hours 20 Individual or group training. Do self study to develop key plant operation questions. Answers are obtained by discussions with production experts and plant investigation.

14. 14 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development BE407 Understanding the process feedstock and final products Know the suppliers of effluent and the customers for treated effluent US: U0005Understand the process and variables in wet end operations in the pulp and paper industry Know the typical properties and composition of effluent and treated effluent Understand how the properties of effluent impacts on the treatment process Understand the reasons for quality standards in treated effluent Be able to construct a spreadsheet with throughputs, specifications, typical results and reasons for each specification Be able to carry out quality checks on the effluent and treated effluent

15. 15 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BE407 The process feedstock and products Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Know the suppliers of effluent and the customers for treated effluent. Know the typical properties and composition of effluent and treated effluent Understand how the properties of effluent impacts on the treatment process Understand the reasons for quality standards in treated effluent Be able to carry out quality checks on the effluent and treated effluent Be able to construct a spreadsheet with throughputs, specifications, typical results and reasons for each specification Assignment Description WHATWHAT HOW Notional Hours 8 Collect Information Use Multi media Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Educational games Case studies Tabulate Develop recommendations Execute, test and evaluate Job assignment Make presentation Draft a report Plant investigation Complete documents Complete a questionnaire Individual or group training. Obtain basic effluent and treated effluent flows, properties and compositions by discussions with production experts. A spreadsheet showing required and typical effluent and treated effluent qualities is drawn up. 1.Learners are supplied with information on effluent quality 2.Have a facilitated group discussion in the plant to determine: by whom effluent is supplied and the customers for the products produced 3.Learners use inputs from production experts to produce a spreadsheet with the following information effluent quality requirements treated effluent quality requirements reasons for each requirement typical, actual qualities impact of deviations from specification on downstream customers (river, re-use, etc.) 4.An introduction is drafted to accompany results

16. 16 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development Know the effect of variations and deviations on the process and treated effluent BE407 Understanding variations in the processes Understand what process deviations could occur in the process Be able to complete all log sheets Understand how a variation in the properties of the effluent will impact on the process Understand what effluent variations could occur in the process US: U0005Understand the process and variables in wet end operations in the pulp and paper industry

17. 17 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BE407 Variations in the processes Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Are able to complete all log sheets. Understand what effluent variations could occur in the process Understand how a variation in the properties of the effluent will impact on the process Understand what process deviations could occur in the process Know the effect of variations and deviations on the process and treated effluent Assignment Description WHATWHAT HOW 1.Learners are supplied with log sheets and assisted to complete them with the help of a production specialist 2.Individually list the effluent and process variations that could occur and the effect each type of variation could have on the final product and / or in downstream processes or products 3.In a facilitated discussion at the site, identify and list the effect each type of deviation could have on the final product and / or in downstream processes or products 4.Tabulate all variations and deviations, their effects and the broad rectification action required and compile the information into a report Notional Hours 6 Individual or group training. Use the information on the feedstock obtained earlier to list quality variations. A facilitated discussion to identify possible process deviations and the downstream effects. Collect Information Use Multi media Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Educational games Case studies List / Tabulate Develop recommendations Execute, test and evaluate Job assignment Make presentation Draft a report Plant investigation Complete documents Complete a questionnaire

18. 18 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development BE407 Apply sampling practices Understand the principles of sampling used in the water treatment process Be able to interpret the test results in terms of the impact on the process and customers Be able to construct a basic spreadsheet for water sources and sample results Be able to do sampling according to plant standards US: U0005Understand the process and variables in wet end operations in the pulp and paper industry

19. 19 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BE407 Apply sampling practices Collect Information Use Multi media Self Study Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Case studies List / tabulate Develop recommendations Execute, test and evaluate Make presentation Complete documents Draft a report Complete a test Learning ActivitiesTopic assessment criteriaAssignment Description WHATWHAT HOW Notional Hours 6 Plant investigation Educational games The assessor will observe and confirm that learners: Understand the principles of sampling used in the water treatment process Are able to do sampling according to plant standards Are able to construct a basic spreadsheet for different water sources and sample results Are able to interpret the test results in terms of the impact on the process and customers Learners are given a short lecture on the statistical basis of sampling practice. Sampling is demonstrated and then done under supervision. A spreadsheet showing required and typical effluent and treated effluent qualities is drawn up. 1.Learners are given a lecture on the statistical basis of sampling practice and tied into the sampling practice in the effluent treatment area. 2.A typical sampling procedure is outlined and a simple checklist compiled 3.Learners view a demonstration of sampling and take a full range of effluent samples under supervision 4.The results of samples are compared to effluent specifications and typical values previously obtained 5.A short report outlines findings Expert demonstration Job assignment

20. 20 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development BE407 By-products recovered in the effluent treatment process Know what potential by-products could be recovered from the recovery process (ligno sulphonate and molded fibrous products) Know what the potential advantages and disadvantages are of recovering potential by- products Understand the basic processes of recovering the potential by-products US: Demonstrate understanding of the water treatment and effluent treatment processes in the pulp and paper industry

21. 21 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BE407 By-products recovered in the effluent treatment process Collect Information Use Multi media Self Study Plant investigation Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Sketch Case studies Do calculations Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a questionnaire Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Know what potential by-products could be recovered from the recovery process (ligno sulphonate and molded fibrous products) Understand the basic processes of recovering the potential by-products Know what the potential advantages and disadvantages are of recovering the potential by-products Assignment Description WHATWHAT HOW Notional Hours 16 Learners are given material explaining the recovery of ligno-sulphonate and molded fibrous products. Learner groups investigate the recovery of these products and make a rough estimate of the benefits vs. costs (actual or potential). Various sources can be involved in estimating costs, laboratory analysis, sales prices, etc. 1.Each group assess the following: a basic plant layout for the recovery of each byproduct approximate capital costs the quantity of each product recoverable the value of each product running costs costs involved in non-recovery 2.A short presentation on the findings is made by each group

22. 22 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development Know the safety standards, procedures and safety equipment used in typical water and effluent treatment operations Be able to identify all potential hazards (including chlorine emission) and indicate actions to reduce/avoid hazards or minimise their effects Know the relevant sections of the OHS Act BE407 Applying SHE in water and effluent treatment Understand the application of emergency procedures Know the potential environmental impact of water and effluent treatment operations, including voluminous water consumption and voluminous effluent production, poor quality effluent and sludge US: Demonstrate understanding of the water treatment and effluent treatment processes in the pulp and paper industry

23. 23 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BE407 Applying SHE in water and effluent treatment Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Know the safety standards, procedures and safety equipment used in typical water and effluent treatment operations Understand the application of emergency procedures Know the relevant sections of the OHS Act Are able to identify all potential hazards (including chlorine emission) and indicate actions to reduce/avoid hazards or minimise their effects Know the potential environmental impact of water and effluent treatment operations, including voluminous water consumption and voluminous effluent production, poor quality effluent and sludge Assignment Description WHATWHAT HOW 1.Learners are supplied with a copy of the safety procedures and the relevant section of the OHS Act 2.Learners individually undertake water and effluent treatment plant inspections and identify all potential hazards. They also assess the potential impact of the plant on the environment. 3.Learners sketch the area and indicate the position of all safety equipment and safety features (e.g. alarm buttons, emergency exists) on it. 4.Recommendations are made to reduce / avoid these hazards, the impact of possible hazards and the plants’ impact on the environment. 5.A short presentation on the findings is made. Notional Hours 8 Learners obtain information through self study. Individuals evaluate the plant area for safety features, potential hazards and environmental impact. Collect Information Use Multi media Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Educational games Sketch Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a test/questionnaire Plant investigation