JKL Automatic Sampler for Horizontal Ducts

Application in Non-Metallic Industry – Dry Bulk Solids

1. General Description

The JKL Automatic Sampler for Horizontal Ducts is an engineered sampling system designed to obtain representative samples of dry bulk solids conveyed through rectangular or circular horizontal ducts, typical of the cement and non-metallic industries (raw meal, ground clinker, lime, gypsum, limestone filler, industrial minerals, etc.).

The system operates under the principle of full cross-stream incremental sampling, ensuring complete interception of the material flow cross-section in accordance with Pierre Gy’s Theory of Sampling (TOS) and internationally recognized industrial sampling standards.

2. Operating Principle

The equipment incorporates a rotary cross-stream cutter (sampling scoop) that traverses the entire cross-sectional area of the material flow inside the duct under the following controlled conditions:

• Constant and uniform linear cutting speed
• Programmable time intervals
• Controlled mechanical drive actuation

Each cutter sweep generates a representative primary increment, which is conveyed through an internal handling system (stainless steel screw conveyor) and discharged into an external sample collection container or secondary reduction system.

This cross-sectional interception method eliminates sampling bias caused by particle size segregation, density variations or flow stratification within the duct.

3. Main Components

The sampler includes:

• Cutting Mechanism
  • Rotary cross-stream cutter fabricated in stainless steel
  • Cutter aperture designed according to ISO-compliant criteria: Minimum cutter opening ≥ 3 times the top particle size (dmax)
  • Rapid discharge geometry to prevent material buildup and overloading
  • Dual drive system with independent gear motors
• Internal Conveying System
  • Stainless steel screw conveyor (auger type)
  • Dedicated gear motor drive
  • Controlled discharge into sample collection compartment
• Structural Frame and Enclosure
  • Carbon steel fully enclosed housing
  • Dust-tight sealing system
  • Inspection viewing windows
  • Sample compartment with access door
  • Reinforced structural support frame for installation on existing ducts
• Electrical and Control System
  • Power and control panel compliant with NEMA 4 enclosure rating
  • Manual and automatic operating modes
  • Programmable timer for adjustable sampling frequency
  • Electrical protections and safety interlocks

4. Engineering Design Criteria

The sampler has been designed considering:

• Uniform linear cutter velocity during full cross-section traversal
• Minimization of wear-prone moving components
• Use of standardized industrial components locally available
• Ease of maintenance (recommended semi-annual inspection)
• Complete environmental contamination protection

Unlike pneumatic sampling systems — which do not guarantee constant cutter velocity — the JKL system utilizes a mechanically driven actuation system, ensuring compliance with industrial sampling standards and metallurgical accounting requirements.

5. Reference Technical Parameters

• Type: Automatic sampler for dry bulk solids in horizontal ducts
• Cutting system: Rotary full cross-stream cutter
• Drive system: Mechanical gear motor
• Internal conveying: Stainless steel screw conveyor
• Electrical protection: NEMA 4 control cabinet
• Wetted/contact materials: Stainless steel
• Operation modes: Manual / Automatic
• Duty cycle: Continuous 24/7 industrial operation

6. Technical Benefits in the Non-Metallic Industry

• Statistically representative sampling
• Elimination of systematic errors due to segregation
• Reliable quality control of kiln feed or grinding circuits
• Improved mass balance accuracy and process control
• Reduced reprocessing and final product variability
• Robust performance in high-dust environments

7. Typical Applications

• Cement kiln feed monitoring
• Raw mill discharge control
• Finished product quality control
• Pneumatic conveying systems
• Lime, gypsum, and industrial mineral duct sampling

8. Standards and Compliance

Designed in accordance with technical criteria based on:

• Pierre Gy’s Theory of Sampling (TOS)
• International bulk material sampling standards
• Good engineering practices for industrial quality control