JKL MAV-5 Flexible Hose Sampler for Abrasive Slurry

1. General Description

The JKL MAV-5 is an automatic flexible hose-type sampler designed for the periodic and controlled extraction of five (5) representative increments of abrasive mineral slurry in pressurized or gravity pipelines.

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-5 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 – Sampling of Slurries
• ISO 12744 – Precision Testing
• ISO 13292 – Bias Testing
• 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-5 can be incorporated into 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-5 Flexible Hose Slurry Sampler represents a robust and efficient solution for the automatic sampling of abrasive mineral slurry, combining mechanical simplicity with advanced statistical sampling foundations.

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.