Rare earth recycling: optimized management with automated emptying of bulk bags

As part of its activity of recycling magnets and processing rare earths, our client was looking for a solution to automatically unload SWARF powder bulk bags. This material, resulting from the grinding and machining of permanent magnets based on neodymium-iron-boron (NdFeB) or samarium-cobalt (SmCo), presents specific risks: flammability, fine dust and oxidability.

The main objective was therefore to ensure safe unloading while ensuring total containment of dust to protect operators and avoid contamination of the production environment.

At the same time, the company wanted to fully automate the process of emptying the bulk bags in order to reach a rate of 15 bulk bags per hour, while minimizing human intervention. It was also crucial to integrate a system for the disposal of empty bulk bags in order to optimize waste management and ensure fluidity of production.

To meet the customer's requirements in terms of safety, productivity and containment, Palamatic Process proposed the installation of an EF500 automated bulk bag emptying station, specially designed for the handling of sensitive and hazardous powders.

The EF500 is equipped with an innovative hydraulic gripper system incorporating two separate gripping devices. A first gripper allows the bulk bag to be handled and held firmly throughout the emptying process. A second clamp, equipped with claws, ensures the retention of the bulk bag after it has been completely emptied. These claws remain locked as long as the bulk bag still contains material and only retract once it has been completely emptied and positioned above the hopper of the baling press.

Emptying of the product is optimized by a bulk-bag cutter blade mounted directly in the emptying hopper. This configuration allows for a clean and wide cut of the bulk-bag fabric, thus ensuring a rapid and even flow of the powder.

In order to limit the spread of fine particles in the production area and to guarantee a healthy working environment for operators, the emptying station is fully enclosed (cased) and equipped with a dedusting line with several strategically distributed suction points. This system allows for homogeneous capture of suspended particles and maintains a clean and safe working environment.

To achieve the rate of 15 bulk bags per hour, the station has been combined with a supply conveyor to store several bulk bags awaiting processing. This system guarantees continuous feeding and avoids any interruption of the production cycle.

At the outlet of the product hopper, a transfer screw has been installed to ensure the homogeneous delivery of SWARF powder to three treatment reactors. This solution optimizes the feeding of downstream equipment and guarantees a continuous flow without interruption.

The empty bulk bags are then automatically directed to a baler, located at the bottom of the hopper, near the emptying hopper. This device allows compacting up to 100 bulk bags into a single bale, thus considerably reducing the volume of waste and optimizing its disposal.

Thanks to this turnkey solution, the customer now benefits from a fully automated process, without direct human intervention on the material, thus ensuring maximum safety for operators and a significant improvement in production efficiency.

The industrial equipment making up the installation with the advantages of the Palamatic Process solution. The installation set up is based on a combination of high-performance industrial equipment, specifically selected to meet the customer's requirements in terms of safety, cadence and containment of fine powders.

• EF500 automated bulk bag emptying station: Equipped with a system of double hydraulic grippers, this station ensures safe handling and optimized emptying of bulk bags. The first gripper picks up and holds the bulk bag during emptying, while the second, equipped with retention claws, stabilizes the bulk bag after emptying before it is discharged to the baler.
• Bulk bag cutter blade integrated into the emptying hopper: This blade guarantees a clean and wide cut of the bulk bag fabric, optimizing the flow of SWARF powder and limiting residues.
• Multi-point dust extraction line: In order to ensure a healthy working environment, the emptying station is fully enclosed (cased) and equipped with a dust extraction system with several strategically distributed suction points. This device allows for homogeneous capture of the fine particles generated during emptying and prevents their dispersion in the workshop.
• Transfer screw at the hopper outlet: To guarantee a continuous supply of the downstream equipment, a transfer screw has been installed to convey the SWARF powder homogeneously to three treatment reactors. This system ensures a constant and controlled flow, without accumulation or load shedding.
• Supply conveyor: In order to maintain an uninterrupted flow of bulk bags, a conveyor has been integrated upstream of the station to store and convey several bulk bags awaiting treatment. This system makes it possible to reach a rate of 15 bulk bags per hour without interruption.
• Baler at the bottom of the hopper: After emptying, the empty bulk bags are automatically directed to a baler located at the bottom of the hopper near the emptying hopper. This baler compacts up to 100 bulk bags into a single bale, optimizing waste management and reducing its volume.

Thanks to this turnkey installation, the customer benefits from a complete, automated and safe solution that meets the strictest standards for the handling and processing of rare earths in powder form.