en.Wedoany.com Reported - Mexican manganese producer Autlán has adopted three E-Air V1100 VSD portable electric compressors supplied by Atlas Copco for compressed air classification of manganese ore in its beneficiation process.
The classifier used by Autlán evaluates materials based on manganese content. When low-grade stones are identified, the system triggers controlled compressed air pulses to eject them from the ore stream, determining how much high-grade material proceeds to the next stage and how much becomes waste rock. This process requires an air supply of 45 Nm³/min at a pressure of 10 bar, with clean, dry air whose temperature does not differ from ambient temperature by more than 20°C.
The distinctive feature of this application is that air supply is not required continuously. Atlas Copco and Autlán jointly analyzed the process requirements and determined, based on the classification cycle, that consumption is intermittent. Following this analysis, Autlán selected three E-Air V1100 VSD electric compressors, with two used for production and the third serving as a backup. Since these portable units are designed for outdoor and harsh environments, they require no fixed installation or compressor room, reducing civil works requirements and allowing air supply to be adjusted according to operational needs.
According to Atlas Copco, the E-Air VSD features a sealed structure with a fluid containment capacity of 110%, helping to prevent leaks. The unit also incorporates fully enclosed motor windings, an IP65-rated controller, an IP67-rated water-cooled variable frequency drive, and a steel enclosure protected by a three-layer anti-corrosion paint system. These features are particularly important in mining facilities exposed to dust, moisture, and severe environmental conditions.
Autlán has also installed a UD+ coalescing filter downstream of the aftercooler, a component that helps remove oil mist, dust, and moisture from the compressed air, reducing the risk of nozzle clogging in the classification system. Air quality directly affects process reliability: contaminated air supply can impair nozzle operation, which in turn affects the precision of mineral separation.
One of the most critical technical features of the E-Air V1100 VSD is the combination of a variable speed drive with a permanent magnet motor. This architecture adjusts power consumption based on actual compressed air demand, particularly under partial load conditions. Additionally, low power demand at startup eliminates the need for over-sizing electrical infrastructure. The unit employs PACE technology, allowing operating pressure to be set between 5 and 12 bar with a regulation accuracy of 0.1 bar. Through the Smart Air Xc4004 controller, operators can view pressure and flow on a seven-inch screen. The built-in aftercooler completes the system, providing suitable compressed air for this application with stringent requirements for air quality and stability.
The Autlán case demonstrates that efficiency in mining operations does not depend solely on increasing installed capacity. In this instance, demand analysis led to the design of a compressed air system for an intermittent application, combined with variable speed electric equipment. The final solution aims to achieve precise classification, lower energy consumption, flexible installation, and reliable operation, while also contributing to improved utilization of high-grade ore.
