JKL MAV-1 Hose-Type Sampler for Abrasive Slurry

1. General Description

El JKL MAV-1 es un muestreador automático tipo manguera flexible diseñado para la extracción periódica y controlada de incrementos representativos de pulpa mineral abrasiva en líneas presurizadas o por gravedad.

The unit operates through the controlled insertion of a wear-resistant hose into the main slurry stream, capturing a proportional fraction of the total flow over a defined time interval, under a time-based or stratified sampling scheme.

The system is engineered for applications such as:

• Flotation feed
• Cyclone overflow/underflow discharge
• Final concentrates
• Tailings
• Regrinding circuits

It is especially recommended where a compact, low-maintenance solution adaptable to restricted installation spaces is required.

2. Operating Principle

The JKL MAV-1 operates under the principle of controlled in-line diversion sampling, whereby:

1. A high abrasion-resistant flexible hose is inserted into the slurry stream.
2. A sampling increment is collected during a predefined time interval.
3. The increment is conveyed to a sample collection vessel or secondary sample reduction stage.
4. The system returns to its standby position until the next programmed cycle.

Sampling can be configured as:

• Time-based (fixed intervals)
• Mass-based (flow-signal integrated)
• PLC-controlled programmable cycles

The design incorporates principles of equiprobability and bias minimization, in accordance with:

• ISO 11794 – Mechanical Sampling of Slurries
• ISO 12744 – Precision Test Procedures
• ISO 13292 – Bias Test Procedures
• Pierre Gy’s Theory of Sampling (TOS)
• AMIRA P754 – Metal Accounting Code of Practice

3. Main Technical Specifications

Mechanical Design

• Structural frame fabricated in ASTM A36 carbon steel or AISI 304 / AISI 316 stainless steel (as specified).
• Internal hose manufactured from reinforced polyurethane or high-abrasion natural rubber.
• Corrosion-resistant mechanical guiding and clamping system.
• Flanged or weld-neck connection to existing pipeline.
• Optional purge and drainage system.

Drive and Actuation System

• Pneumatic or electric actuator.
• Integrated PLC control or DCS interface capability.
• Programmable insertion and retraction cycles.
• Position feedback signals (extended / retracted status).

Typical Operating Parameters

• Slurry density: 1.2 – 2.0 t/m³
• Solids concentration: 25 – 65 % by weight
• pH range: 2 – 12
• Line pressure: up to 6 bar (design dependent)
• Maximum particle size: up to 3–6 mm (hose diameter dependent)

4. Representativeness Fundamentals

The MAV-5 design addresses the primary components of sampling error as defined by the Theory of Sampling:

✔ Delimitation Error (DE) Minimization
The hose entry geometry is designed to intercept the slurry flow transversely, ensuring correct increment delimitation.

✔ Extraction Error (EE) Minimization
Controlled cutting time and appropriate internal cross-section prevent segregation or preferential selection.

✔ Weighting Error (WE) Control
Optional integration with flowmeters ensures mass-proportional sampling.

✔ Bias Control
Capability for experimental bias validation in accordance with ISO 13292.

✔ Precision Control
Interleaved testing procedures according to ISO 12744.

5. Technical Advantages

• Compact and modular design.
• High resistance to abrasive slurry conditions.
• Low power consumption.
• Simplified maintenance (quick hose replacement).
• Fully integrable into JKL SMM Modular Sampling Systems.
• Suitable for metallurgical accounting audits and reconciliation processes.

6. Application in Metallurgical Accounting

The MAV-1 may form part of a structured sampling system for:

• Metallurgical balance reconciliation.
• Recovery control.
• Online grade monitoring.
• Cyclone performance validation.

In compliance with the AMIRA P754 Code of Practice, ensuring:

• Full traceability.
• Operational transparency.
• Statistical error control.
• Elimination of systematic sampling bias.

7. Optional Features

• Automatic washing system.
• Blockage detection sensor.
• Integration with online analyzers (e.g., XRF).
• Dual-line configuration for sample and duplicate (check) sample.
• Anti-sedimentation system.

8. Technical Conclusion

The JKL MAV-1 represents a robust and efficient solution for automatic abrasive slurry sampling, combining mechanical simplicity with advanced statistical sampling principles.

Proper implementation enables:

• Reduction of metallurgical balance uncertainty.
• Improved process data reliability.
• Compliance with international sampling standards.
• Assurance of integrity in technical and financial audits.