Cleveland Cascades Ltd

Providing the industry standard loading solutions

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

The Cascades Concept

Cleveland Cascades the innovator

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

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.

above: Materials flowing at a

controlled speed through the
cascade system

above: Shroud prevents wind blown

dust dispersion

Using this technology, dust generation is

practically eliminated at source without the
need for expensive and energy intensive
dust extraction and filtration systems.

Uncontrolled Loading
as shown below generating
a real dust nuisance for the
local inhabitants and severe
environmental pollution

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

Bulk Material Handling

Cleveland Cascades the innovator
Manufacturing expertise
Cleveland 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 application
Loading systems can be supplied
to match a wide range of flow rates
and are suitable for a variety of
applications including:
Ship & Barge loading
Truck & Trailer loading
Tanker loading
Railcar loading
Transfer stations
Flat stores
Railcar or truck reception pits

Design excellence
Our 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 materials
Lining systems for corrosive or high
temperature materials
Folding systems to maximise air draught
Variable velocity systems
Provision of sensors, controls and interfaces
Robust electrical and mechanical
components
Chute retraction anti spill valves
ATEX compliance
Wide range of loading capacities
Short or long length chutes available
Food grade standard models available
Trimming devices for level hatch filling
Load monitoring systems
Anti static systems
Autospill facilities
Material handling solutions
In 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.

Above: Cleveland Cascades

guarantee dust pollution
levels down to 5mg/m3

At the forefront of retractable loading chute design and manufacture

Cleveland Cascade
Applications

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

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.

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

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.

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

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.

above: Potash storage

At the forefront of retractable loading chute design and manufacture

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

Cascade
Interface Data

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

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

Above left: Solutions tailored to integrate with existing ship loading systems.
Above right: Folding systems for ease of operation

Cascade
Chute Options

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

above: Flexible Skirts seal the chute

outlet to the material (Shroud removed
showing material flow)

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.

At the forefront of retractable loading chute design and manufacture

Below - Gimbal mounting allows chutes to be freely supported eliminating

risk of damage if the chute fouls the ships hold or other obstructions

Cascade
Technical Data

Head Chute with entrainment

deflector to align the material
flow to the Cascade chute inlet.

G
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.

A
B

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.

C
F
A
B
C
D
E
F
G

Cable Winder connecting the head to the outlet

Load Cell Overload Protection
Material Level Detection - Automated Retraction
Raise/Lower Wire Rope Winch
Radial Distributor Chute with Motorised Slewing
Skirted Outlet - Option to Radial Distributor
Pivoted Mounting for variable boom angle

Free fall loading chutes

The T and C Series

Above: The T Series Chute shown fully extended

The T and C
Series
The T Series
For 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 Series
Similar 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.

above: T Series chute shown

with radial distributor

above: C Series
chute fitted with flexible skirt

At the forefront of retractable loading chute design and manufacture

Free Fall
Tanker Loading Chutes

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

Integrated chute designs tailored for your

specific applications based on our wealth of
experience handling powders and dry bulk solids
worldwide

The C Series
The 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

10

Cleveland Cascades
Products and Services

Above: Free fall chute mounted on a telescopic radial mobile belt

conveyor used for stacking and ship loading

Product Range
The 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.

Cascade chute
shown fully
retracted
demonstrating
compact design

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.

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

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

At the forefront of retractable loading chute design and manufacture

11

Security

Industry Experts

Cleveland 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.

Cleveland 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
Buhler
Thyssen Krupp
Alcan Alesa
BHP
McGregor Bulk
Repsol
Rio Tinto
FAM
Heidelberg Cement Statoil
Lafarge
Aumund
Cementi Rossi
and many others

Experience
The 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.

Awards
The 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

Unparalleled Experience
Our design engineers are highly experienced in
integrating our loading chutes into your existing
or new facilities, typical materials handled include:
Potash
Animal feed
Finished cement
Fly ash
Gypsum
Sulphur
Bentonite
Olivine sand
Soda ash
and many others

Cereals
Petroleum coke
Salt
Cement clinker
Limestone
Perlite
Grain
Phosphate
Quartz

Pelletised materials
Sugar
Sodium sulphate
Limenite
Alumina
Coal
Bauxite
Urea
Kaolin

Pollution Monitoring and Measurement

Cleveland 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.

1998 Queens award for export achievement

Contact Cleveland Cascades Ltd

A1045

A174

UK Headquarters, Unit 22, Dukesway,

Teesside Industrial Estate,
Thornaby, Stockton-on-Tees
Cleveland, TS17 9LT, United Kingdom
Tel: +44 1642 753260
Fax: +44 1642 7532700
E-mail: enquiries@clevelandcascades.co.uk
Web: www.clevelandcascades.co.uk

Agents

A19

Teesside
Industrial Estate

A1044