FdSc Clay Technology

Engineering & Mathematics

The principles of mathematics, and mechanical and electrical engineering are fundamental to the operation of production, processing and mobile plant. This module aims to develop an understanding of the principles and concepts of basic mechanics and to introduce the basic theories and concepts of electricity, electrical circuits, electrical measurement, magnetism and electromagnetic induction. Furthermore, the module aims to develop a wider understanding of the use of mathematical principles and techniques and apply them to applications in the fields of engineering and mineral products technology.

Industry Introduction

This module provides the learner with an underpinning knowledge and understanding of the Mineral Products Industry. The module will introduce the learner to the economic importance of the industry, its role in modern economies, and how it underpins the very fabric of civilisation. It will explore its roots in geosciences, providing an understanding of the chemistry and geology of the planet and its application in the evolution and exploitation of the minerals its mines. It explores the widespread nature of the industry across the United Kingdom and globally. Fundamental to working in this industry, particularly in the operational areas, is an understanding and competence in the recognition and application of health, safety, and environmental awareness. Furthermore, the leaner will gain knowledge of emergency planning procedures and the safe use and guarding of machinery and equipment used within the mineral products sector. Finally, learners will be introduced to both first aid in the context of the work environment and also mental health to keep pace with industry guidelines and best practice.

Industry & the Environment

Central to this module is the development of knowledge in the field of geology that is beneficial to the safe and effective operation of mineral extraction and construction sites and the identification of geological hazards. This module also introduces the general concepts of workplace health and safety with particular attention to noise and hazardous substances. A further element to this module is the introduction of sustainability and in particular corporate, social responsibility, standards, and governance in the context of the mineral products industry. Key topics are discussed and developed including climate change, net zero and performance reporting. Furthermore, the impact of biodiversity, geodiversity and natural capital as applied to the mineral products industry are described and discussed.

Learning, Thinking & Study Skills in Higher Education

This module gives learners the opportunity to identify and reflect on their own strengths and weaknesses, to enable personal developmental planning needs, to be identified as they begin to progress through their learning journey within the Mineral Products industry. It provides learners with the basic knowledge and tools required to recognise and review their personal learning and thinking skills. It explores with them how they can identify and assess their developmental progress and equips them with the skills needed for academic study, writing and progression. It will provide examples of how they can use this knowledge and the associated tools within the context of their workplace in the Mineral Products industry. This module will also provide learners with an introduction to British Values, PREVENT and Safeguarding followed by leadership, which will supplement their developmental and employability potential within the work context. In addition, specifically for apprenticeship learners this module will introduce the Knowledge and Skills required to prepare and develop an e-portfolio required for End Point Assessment purposes.

Engineering Principles & Theory

The engineering concept within the mineral products sector is fundamental to the successful operation of static and mobile plant. This module will develop an understanding of the theory and principles of mechanics and their application within the sector. The principles and concepts associated with heat and fuels and their application in burners are introduced and awareness of engineering materials and of the fundamental principles of corrosion in relation to beams and fixed structures is developed. Furthermore, this module will focus on an understanding of the principles and concepts associated with the use of AC electricity and its application within the sector before extending the students understanding of electrical power transmission systems, electric motors and generators.

Construction Products Technology

Mineral resources form the basis of most products used in construction. This module develops knowledge of the technology, EN standards, specifications and other requirements that apply to these products. It will include aspects such as the methods used to sample and test aggregates, bituminous mixtures, cement and concrete, and bricks in a safe manner. In addition, the module will develop knowledge of the technology, characteristics and Standards used in customer specifications for these products. The module also provides knowledge of the techniques used to manage product quality to satisfy the needs of the customer.

Business & Operational Management

This module develops the operational, business and financial knowledge and skills necessary to achieve the effective management of a mineral products facility. This includes an understanding of the human implications of running a successful business. The module also recognises the importance of communication (written and none written skills), people and values in developing a positive workplace culture. Furthermore, the concepts and principles of asset management are introduced to develop skills in relation to performance measurement and monitoring. To meet with modern day challenges students are also provided with the fundamentals of building a sustainable business and the concept of cyber security. Additionally, for apprentices this module supports and develops completion of the e-portfolio required for End Point Assessment purposes.

Clay Evaluation & Investigation

This module provides the learner with an underpinning knowledge of the techniques used to identify potential sources of clay for use in a range of clay products. It will cover the areas of practical and scientific knowledge required to understand the environmental and geological factors that can have an impact on the development of a clay extraction site at the appropriate level within the clay technology industry. It will consider the methods and techniques used to investigate and evaluate a potential source of clay, including site survey and site investigation methods. It includes the study of the ways of describing the characteristics and classification of clay, including laboratory testing and terminology used in site investigation reports.

Production Facility Engineering

In relation to the Mineral Products industry, this module develops an awareness of the need for lubrication, bearings, and an understanding of the principles and concepts associated with hydraulic systems, their application and associated dangers. Also, the module introduces mechanical power transmission systems and develops an understanding of the behaviour of gases and how these are applied to the construction and operation of compressors, pumps and internal combustions engines. An understanding of asset prioritisation and plant operating and planned, preventative maintenance schemes are also developed along with process control concepts in relation to automation and digitisation. Furthermore, the module develops knowledge and awareness in relation to 3 phase and circuit control, power factor and correction, electrical safety, earthing, earth leakage and overcurrent protection.

Clay Winning, Preparation & Forming

This module provides the learner with an underpinning knowledge of the methods and techniques used to extract, stockpile, process and mould clay into a form that is ready for drying and firing as a clay product. It provides an understanding of the issues and constraints associated with crushing and size reduction of clay lumps and particles. The module will review the various processes used to prepare the clay so that it can be used to produce clay products in a safe way that also respects the environment. It includes the methods that can be used to adjust and modify the characteristics of the processed clay and includes how the moulded clay can influence the dimensions and shape of the finished clay product. It includes a study of the techniques used to control the forming process. The module will offer knowledge of how surface treatments can be used to create particular surface characteristics and properties in the finished clay product. The module also provides an understanding of how surface finishes can be used to provide resistance to specified ground conditions and end-use environments.

Clay Drying & Firing

This module provides the learner with an underpinning knowledge of the techniques used to dry and then fire clay products. It will cover the areas of practical and scientific knowledge required to perform at the appropriate level within the clay technology industry and provide the knowledge and understanding of the drying and firing processes that produce different types of clay products and the influence of drying and firing techniques on their characteristics. It will consider the methods used to prepare (set) dried and formed clay products before they are fired and an understanding of different methods of removing moisture, including the rate of drying and associated process controls. It includes the study of the of the range of techniques and equipment used to fire clay products, including the chemistry and economics of firing; the economic operation of kilns; statistical process control techniques; and safe operation in a way that complies with pollution controls. The module will offer an awareness of the published product Standards that define the characteristics of finished clay products, including the control of product conformity and an understanding of the methods used to stack and pack finished clay products in a way that is appropriate to the method used to deliver it to the customer. The module also examines the management of customer requirements, including quality management systems and an awareness of environmental aspects.

Mineral Products Workbased Project

This module brings together the learner’s knowledge of the industry gained from the programme and asks them to offer a detailed discussion of a problematic area and locate it within the wider context of current academic and professional thinking as presented in the literature and within the context of the area of the Mineral Product industry in which they work. Learners will be expected to demonstrate the ability to diagnose an organisational issue, to present this issue in a coherent manner, and to draw conclusions from their reading, personal analysis and workplace experience.