Cleveland Cascades LtdProviding the industry standard for loading solutions

Unique and innovative solutions for the economic control of dust pollution, degradation and segregation

Shiploading represents a major problem since the material must be delivered to the vessel hold from a boom conveyor often 20 metres or more above the hold floor generating a high terminal velocity and often an extreme dust hazard.

The Cascade solution overcomes this problem by directing the material to flow down a series of inclined cones which limits the flow velocity and thereby prevents particulate separation, material degradation and segregation.

Using this technology, dust generation is practically eliminated at source without the need for expensive and energy intensive dust extraction and filtration systems.

For multi-bulk operations where widely different materials must be handled, the VariFlow system is available. To optimise flow rate the VariFlow can operate in three modes. In standard mode, cone inclination is maintained at a fixed angle to suit the range of materials anticipated. In remote mode, the cone angles are adjusted to optimise flowrate for a particular material. In intelligent mode, sensors in the system monitor the materials speed of descent and the cone angles are constantly adjusted to optimise the flow rate.

above: Materials flowing at a controlled speed through the cascade system

When material is allowed to free fall uncontrolled it accelerates and as the velocity increases dust particles within the material separate and are ejected by the fast moving air stream created.

The Cascades ConceptCleveland Cascades the innovator

above: Shroud prevents wind blown dust dispersion

With a cascade system, materials descend in mass flow eliminating the entrapment of air

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At the forefront of retractable loading chute design and manufacture

Bulk Material HandlingCleveland Cascades the innovator

Uncontrolled Loadingas shown below generatinga real dust nuisance for thelocal inhabitants and severeenvironmental pollution

Above: Cleveland Cascades guarantee dust pollution levels down to 5mg/m3

Above - from left to right: The Cascade Concept, Potash Export Terminal, Phosphate Loading Without Effective Dust Control

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Material handling solutionsIn addition to your loading chute requirements, Cleveland Cascades Ltd can assist you with other dry bulk material handling projects such as skirtless transfer stations for dusty materials.

Manufacturing expertiseCleveland Cascades Limited are recognised as industry leaders in the application of bulk material loading systems in a variety of diverse situations. Whether you require a basic loading chute or a system which incorporates the latest technologies to control dust production, material degradation and segregation, we have systems in our range to fully meet your needs. Where dust control is an important consideration we can supply systems guaranteeing dust emission levels as low as 5mg/m3. In all cases, robust construction means reliable operation and easy maintenance.

Systems for every applicationLoading systems can be supplied to match a wide range of flow rates and are suitable for a variety of applications including:

Ship & Barge loadingTruck & Trailer loadingTanker loadingRailcar loadingTransfer stationsFlat storesRailcar or truck reception pits

Design excellenceOur range of standard designs can incorporate special features to help ensure optimised performance, reliability and best value, facilities available include but are not limited to:

Lining systems for abrasive materialsLining systems for corrosive or high temperature materialsFolding systems to maximise air draughtVariable velocity systemsProvision of sensors, controls and interfacesRobust electromechanical componentsChute retraction anti spill valvesATEX complianceWide range of loading capacitiesShort or long length chutes availableFood grade standard models availableTrimming devices for level hatch fillingLoad monitoring systemsAnti static systemsAutospill facilitiesControl panel manufacture

Ship loading

Both Alumina and Cement are very dusty materials and represent a real challenge but the Cascade solution delivers results.

Cleveland Cascade Applications

Above left: Cascade system mounted to a ship loader handling sulphur. Above right: Cascade system loading Alumina to ships hold without dust production. Top right: Open hatch loading of Cement.

Hundreds of reference installations worldwide handling a wide range of dry bulk cargoes the Cascade design has established an enviable reputation for efficiency and performance

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At the forefront of retractable loading chute design and manufacture

Storage

Using the Cascade to reduce dust emissions within storage operations improves the working environment and reduces potentially dangerous dust accumulation.

Illustrated above left dust controlled loading of Gypsum at a storage facility.

Illustrated above middle the Cascade is mounted to a travelling tripper conveyor and arranged to discharge coal to storage bays.

Illustrated above right the Cascade is mounted to an extended inlet chute handling Cement Clinker to control dust within the mill bunker building.

Illustrated right the Cascade is mounted to a travelling stacker for handling Potash within a horizontal storage facility.

Controlled material transfer from the distribution conveyor system down to floor level effectively eliminates dust pollution, material degradation and segregation thus maintaining quality and improving the working environment

above: Potash storage

Above - from left to right: Loading Alumina, Gypsum storage facilities, Coal storage, Cement Clinker storage

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CascadeInterface Data

Above left: Solutions tailored to integrate with existing ship loading systems.

Above right: Folding systems for ease of operation

Below, where air draught is an important consideration in order to accommodate larger ships, folding systems can be provided which helps to avoid striking ship sides during positioning

Below - Cascade mounted to a travelling Shiploader with a hinged outloading boom able to be raised vertical for stowage and travelling between the vessel holds

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System Integration Cleveland Cascades Limited understand the importance of being able to provide loading chutes which can be easily integrated into designs for existing and new ship loading systems while incorporating special features to meet the users special requirements.

Cascade Chute fitted to a radial and luffing Shiploader Outloading Boom including entrainment head chute with pivoted mounting shown here with the chute fully retracted

At the forefront of retractable loading chute design and manufacture

CascadeChute Options

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Permits material to be accurately positioned within the vessel hold to maximise the stowed volume under deck sides with the minimum of machine movements.

The Trimmer (or Radial mounted Distributor) is mounted to a precision slewing ring with electric motor drive controlled either from the drivers cabin or hand held remote control station.

above: Flexible Skirts seal the chute outlet to the material (Shroud removed showing material flow)

Cone Lining Cones may be lined in UHMWP plastic material, abrasion resistant steel plates or as illustrated above in Ceramic Tile applied in our own workshops and offering remarkably long service life. Controller Module

Chute control may be integrated to the clients existing PLC equipment or independently operated with a dedicated controller as illustrated.

Rotating Trimming Chute

above: The Cemglide chute designed for closed hatch loading of free flowing materials such as cement

CascadeTechnical Data

Below - Gimbal mounting allows chutes to be freely supported eliminating risk of damage if the chute fouls the ships hold or other obstructions

B

E

G

A

C

D

F

Illustrated right the Cascade Chute extended showing the alternate interlocking inclined cones supported on flexible straps to control the cone angle appropriate to the materials to be loaded.

Illustrated far right the Cascade is fully retracted showing the cones stacked one above the other in close proximity to minimise the retracted length.

Picture right shows the outlet valve which isolates the chute during machine or boom movements preventing dust spillage.

Head Chute with entrainment deflector to align the material flow to the Cascade chute inlet.

A Cable Winder connecting the head to the outletB Load Cell Overload ProtectionC Material Level Detection - Automated RetractionD Raise/Lower Wire Rope WinchE Radial Distributor Chute with Motorised SlewingF Skirted Outlet - Option to Radial DistributorG Pivoted Mounting for variable boom angle

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At the forefront of retractable loading chute design and manufacture

The T and C Series

Above: The T Series Chute shown fully extended

The T SeriesFor applications where dust control is not required the T Series telescopic chute design provides a simple and economical solution.

Comprising rolled steel shells with stiffening rings terminated either to an open outlet or slewing ring for a radial distributor.

This chute is not designed to control dust emissions or degradation but eliminates wind blown losses and prevents uncontrolled dispersion mainly in ship loading and storage applications.

The C SeriesSimilar in principle to the T Series design internally with telescopic tubular steel sections the C Series has an outer shroud allowing dust extraction from the chute outlet.

This allows handling of dusty materials and provides an economical alternative to the more sophisticated Cascade solution in appropriate applications.

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above: “C” Series chute fitted with flexible skirt

above: “T” Series chute shown with radial distributor

Free fall loading chutesThe T and C Series

Free Fall Tanker Loading Chutes

Integrated chute designs tailored for your specific applications based on our wealth of experience handling powders and dry bulk solids worldwide

The C SeriesThe C Series free fall principle may be effectively used for Tanker Loading controlling dust down to the tanker inlet.

With the addition of the Cone Closure valve dust material leakage is effectively eliminated when the chute is not operating.

Above: Loading Kaolin

The C Series design with integrated dust extraction evacuates the dust laden displaced air eliminating local dust pollution

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At the forefront of retractable loading chute design and manufacture

Product RangeThe Cascade design with inclined cones is available in three sizes. According to the cone diameter, they are able to accommodate flow rates in excess of 4,000 cubic metres per hour depending upon the material flow characteristics.

Extending the range of economical applications the Free Fall chute designs (as illustrated above) offers a competitive and effective alternative, particularly where materials are not dusty or are slightly sticky.

Whilst the free fall arrangement cannot compete with the Cascade for ultimate dust control there are many applications where the performance is entirely acceptable at a lower price point.

All designs may be supplied for use in Ship Loading, Flat Storage, Tanker Loading and Stockpiling complete with the appropriate facilities as a complete engineered package.

EngineeringOur comprehensive and experienced engineering services are available on demand to integrate chute designs to existing or new materials handling equipment.

ServiceOur products are supported by highly skilled supervising engineers for site installations and commissioning of all our equipment.

Cascade chute shown fully retracted demonstrating compact design

Above: Free fall chute mounted on a telescopic radial mobile beltconveyor used for stacking and ship loading

Cleveland CascadesProducts and Services

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SecurityCleveland Cascades Limited is now firmly established as an accepted authority in the design and implementation of dust controlled loading chutes with many successful references worldwide. Our loading systems are mainly utilised for ship loading but are also used during flat store filling, road, tanker, and railcar loading as well as in conveyor transfer stations. Our systems are particularly effective where the prevention of dust pollution and material degradation or segregation is a priority. Cleveland Cascades Ltd is able to provide bank guarantee security for stage payments and extensive warranty schemes.

ExperienceThe Cascade chute was designed and developed jointly by Steve Maxwell and Ian Barnard, Chairman and Managing Director of Cleveland Cascades Ltd. Ian Barnard was the Engineering Manager of the Cleveland Potash bulk terminal at Tees Dock where in the latter stages he developed the Cascade loading system.

AwardsThe Cleveland Cascade System is a unique and patented loading chute that minimises dust emission, degradation and segregation. It is one of the more important developments in bulk material handling in recent years and holds the following awards:

1995 Engineering Council Environment Award for Engineers

The 1996 Teesside Business Environmental Award

1997 Queens award for Environmental Achievement

1998 Queens award for export achievement

2009 Queens award for International Trade

Industry ExpertsCleveland Cascades Ltd have a wealth of experience in the successful completion of projects worldwide, our customers include many notable organisations in their respective fields including: Cleveland Potash Conoco Philips BuhlerThyssen Krupp Alcan Alesa BHPMcGregor Bulk Repsol Rio TintoFAM Heidelberg Cement StatoilLafarge Aumund Cementi Rossiand many others

Unparalleled ExperienceOur design engineers are highly experienced in integrating our loading chutes into your existing or new facilities, typical materials handled include:

Potash Cereals Pelletised materialsAnimal feed Petroleum coke SugarFinished cement Salt Sodium sulphateFly ash Cement clinker LimeniteGypsum Limestone AluminaSulphur Perlite CoalBentonite Grain BauxiteOlivine sand Phosphate UreaSoda ash Quartz Kaolinand many others

Pollution Monitoring and MeasurementCleveland Cascades Limited can help you to measure your current dust emission performance using the latest air sampling techniques. This service can be an important part of your environmental protection measures and to evaluate the performance of your existing and new loading system.

Agents

Contact Cleveland Cascades LtdUK Headquarters, Unit 22, Dukesway,Teesside Industrial Estate,Thornaby, Stockton-on-TeesCleveland, TS17 9LT, United Kingdom

Tel: +44 1642 753260Fax: +44 1642 753270

E-mail: enquiries@clevelandcascades.co.ukWeb: www.clevelandcascades.co.uk

Teesside Industrial Estate

A1045

A1044

A19

A174