Explosion-proof controls enable dust-free loading of dry bulk materials
A range of hazardous area equipment, including terminal boxes, control stations, emergency stop controls and enclosures manufactured by Cooper Crouse-Hinds (CEAG), are being used on loading systems for handling dry, potentially-explosive bulk materials, including cement, alumina, sugar, petroleum coke, grain and sulphur.
Based in Stockton-on-Tees, Cleveland Cascades Ltd designs and manufactures a range of custom-designed, retractable loading chutes for the handling of dry bulk materials. Using its patented Cascade system, the company has more than 400 systems in operation around the world in various ship, silo, rail and road tanker loading applications. The company is considered to be a market leader in its field and its product the industry standard.
Ray Ollis, Electrical Design Engineer at Cleveland Cascades Ltd comments: “We’ve been purchasing CEAG equipment for many years now, via Scattergood & Johnsons Ltd, our local distributor in Leeds. When it comes to offering loading chutes for hazardous environments, we provide a de-tailed design specification to Scattergoods, who would then source the required control stations and terminal boxes from CEAG. Up to now, the CEAG equipment has been very reliable and we’ve never had a single problem from the customer once we’ve installed the system.”
All other dry bulk loading systems currently available on the market enable bulk material to free-fall and in doing so, pull volumes of air down with the falling material. This air needs to escape at the base of the chute and when doing so, carries the separated material particles, causing highly visible dust emissions, which is not only a nuisance to the local environment but which also creates a potentially explosive atmosphere. These systems would require a dust extraction to attempt to recover this dust-laden air.
As Ollis explains: “Unlike free fall chutes, the Cleveland Cascade chute gently supports the material being loaded all the way down the vertical length of the chute and in doing so, maintains a con-stant and low velocity, which together with the cone shape, keeps the material in mass flow form. The low velocity means the material does not pull air down with it and so if there is no air to escape, there is no dust generated.”
The Cleveland Cascade system constrains the material to flow in a zigzag path through inclined cones to limit the flow velocity and therefore prevent particulate separation, material degradation and segregation. In this way, dust generation is virtually eliminated at source, without the need for expensive and energy-intensive dust extraction and filtration systems. The Cleveland Cascade system is so successful that Cleveland Cascade is the only company in the world who can currently guarantee dust emission levels down to less than 5 mg/m3.
Ollis continues: “We normally have to retrofit our loading chute to the ship or tanker. This involves a lot of engineering effort, both mechanical and electrical. For example, if the customer needs to load 200 tonnes an hour of cement to a tanker, we have to design our chute and associated control equipment to cater for this. This means we sometimes have to use customised control stations and junction boxes.”
According to Ollis, chute controls can be integrated with the customer’s existing PLC equipment or operated independently with a dedicated controller. The controls for the chute would normally be located in a gallery, close to the conveyor, or remotely. In either situation, especially when ATEX certification is required, CEAG control stations are used, which typically comprise emergency stop-start controls, reset and raise controls, stainless steel or plastic enclosures (depending on the appli-cation) and terminal boxes.
In order to monitor the loading of dry bulk materials, a pair of level probes are located at the bottom of the loading chute, terminated to a CEAG junction box. If the job requires full installa-tion, Cleveland Cascade would then provide full chute controls.
“People are starting to wake up to the ATEX regulations and more jobs are now including this type of hazardous area equipment. Out of the nine enquiries currently on my desk, three require ATEX approved control equipment. We’re currently tendering for a contract in Spain with the oil com-pany Repsol, which involves a lot of ATEX Zone 21 control equipment. It’s for a loading system for filling open road wagons and we will use CEAG controls and terminal boxes for this application,” says Ollis.
Cooper Crouse-Hinds (UK) Ltd.
As part of the Cooper Industries Group, Cooper Crouse-Hinds (UK) Ltd is the number one company in the field of explosion protection. Committed to technological progress, the company develops and manuactures a range of products that cover all the requirements currently placed on modern, explosion-protected, electrical installation technology, including illumination, safeguarding, signal-ling, controlling, instrumentation and distribution of electrical energy in potentially explosive atmospheres. In the company’s production plants in Germany, England and Spain, the company manufactures a wide range of products for explosion protection.
Cooper Crouse-Hinds supplies products that comply with all the latest directives and standards – worldwide. In addition to systems and components built to ATEX standards, the company also provides solutions that have been certified to both IEC and NEC standards. Moreover, the company also has a large number of other national approvals, e.g. for Eastern European countries, China and North America. With Cooper Crouse-Hinds you can get all you need from one source.
Explosion-proof Controls
Explosion-proof controls enable dust-free loading of dry bulk materials
A range of hazardous area equipment, including terminal boxes, control stations, emergency stop controls and enclosures manufactured by Cooper Crouse-Hinds (CEAG), are being used on loading systems for handling dry, potentially-explosive bulk materials, including cement, alumina, sugar, petroleum coke, grain and sulphur.
Based in Stockton-on-Tees, Cleveland Cascades Ltd designs and manufactures a range of custom-designed, retractable loading chutes for the handling of dry bulk materials. Using its patented Cascade system, the company has more than 400 systems in operation around the world in various ship, silo, rail and road tanker loading applications. The company is considered to be a market leader in its field and its product the industry standard.
Ray Ollis, Electrical Design Engineer at Cleveland Cascades Ltd comments: “We’ve been purchasing CEAG equipment for many years now, via Scattergood & Johnsons Ltd, our local distributor in Leeds. When it comes to offering loading chutes for hazardous environments, we provide a de-tailed design specification to Scattergoods, who would then source the required control stations and terminal boxes from CEAG. Up to now, the CEAG equipment has been very reliable and we’ve never had a single problem from the customer once we’ve installed the system.”
All other dry bulk loading systems currently available on the market enable bulk material to free-fall and in doing so, pull volumes of air down with the falling material. This air needs to escape at the base of the chute and when doing so, carries the separated material particles, causing highly visible dust emissions, which is not only a nuisance to the local environment but which also creates a potentially explosive atmosphere. These systems would require a dust extraction to attempt to recover this dust-laden air.
As Ollis explains: “Unlike free fall chutes, the Cleveland Cascade chute gently supports the material being loaded all the way down the vertical length of the chute and in doing so, maintains a con-stant and low velocity, which together with the cone shape, keeps the material in mass flow form. The low velocity means the material does not pull air down with it and so if there is no air to escape, there is no dust generated.”
The Cleveland Cascade system constrains the material to flow in a zigzag path through inclined cones to limit the flow velocity and therefore prevent particulate separation, material degradation and segregation. In this way, dust generation is virtually eliminated at source, without the need for expensive and energy-intensive dust extraction and filtration systems. The Cleveland Cascade system is so successful that Cleveland Cascade is the only company in the world who can currently guarantee dust emission levels down to less than 5 mg/m3.
Ollis continues: “We normally have to retrofit our loading chute to the ship or tanker. This involves a lot of engineering effort, both mechanical and electrical. For example, if the customer needs to load 200 tonnes an hour of cement to a tanker, we have to design our chute and associated control equipment to cater for this. This means we sometimes have to use customised control stations and junction boxes.”
According to Ollis, chute controls can be integrated with the customer’s existing PLC equipment or operated independently with a dedicated controller. The controls for the chute would normally be located in a gallery, close to the conveyor, or remotely. In either situation, especially when ATEX certification is required, CEAG control stations are used, which typically comprise emergency stop-start controls, reset and raise controls, stainless steel or plastic enclosures (depending on the appli-cation) and terminal boxes.
In order to monitor the loading of dry bulk materials, a pair of level probes are located at the bottom of the loading chute, terminated to a CEAG junction box. If the job requires full installa-tion, Cleveland Cascade would then provide full chute controls.
“People are starting to wake up to the ATEX regulations and more jobs are now including this type of hazardous area equipment. Out of the nine enquiries currently on my desk, three require ATEX approved control equipment. We’re currently tendering for a contract in Spain with the oil com-pany Repsol, which involves a lot of ATEX Zone 21 control equipment. It’s for a loading system for filling open road wagons and we will use CEAG controls and terminal boxes for this application,” says Ollis.
Cooper Crouse-Hinds (UK) Ltd.
As part of the Cooper Industries Group, Cooper Crouse-Hinds (UK) Ltd is the number one company in the field of explosion protection. Committed to technological progress, the company develops and manuactures a range of products that cover all the requirements currently placed on modern, explosion-protected, electrical installation technology, including illumination, safeguarding, signal-ling, controlling, instrumentation and distribution of electrical energy in potentially explosive atmospheres. In the company’s production plants in Germany, England and Spain, the company manufactures a wide range of products for explosion protection.
Cooper Crouse-Hinds supplies products that comply with all the latest directives and standards – worldwide. In addition to systems and components built to ATEX standards, the company also provides solutions that have been certified to both IEC and NEC standards. Moreover, the company also has a large number of other national approvals, e.g. for Eastern European countries, China and North America. With Cooper Crouse-Hinds you can get all you need from one source.
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Photos::
Hazardous area control equipment from Cooper Crouse-Hinds on a sulphur chute destined for Russia
Attachments
cleveland_cascades_standard (JPG)
cleveland_cascades_sulphur- (JPG)
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