To scale back the dangers of transferring sizzling slag, OEMs Volvo CE and Liebherr have developed steel-mill wheel loaders specifically tailored for the duty – and within the course of created the most secure most sturdy autos of their class
Wheel loaders are important machines throughout quite a lot of industries because of their adaptability for working with totally different supplies. In metal mill environments, wheel loaders present an important position to maneuver sizzling slag. These impurities from metal making are faraway from the furnace for reuse or repurposing into aggregates. Typically likened to lava, this molten slag may be discovered at excessive temperatures as much as round 1,200°C presenting a harmful and high-risk working atmosphere for the car and its operator. Because of this, many equipment producers provide steel-mill particular wheel loaders to go well with this excessive utility.
“At Liebherr, buyer satisfaction and security are on the forefront of all options. For the work on this atmosphere, security and luxury are the highest priorities for Liebherr wheel loaders. Because of this, there are numerous gear choices that cut back fatigue and allow secure and comfy working,” explains Mark Walcher, product supervisor for XPower heavy gear at Liebherr.
“Liebherr gives preparation for a protecting air flow system that filters particles and gasses and moreover seals the cab”
Driver security
In addition to intense warmth, metal mills may be dusty and produce poisonous fumes that will make it not possible for operators to work safely for prolonged durations of time. To fight this, wheel loaders for warm slag dealing with are outfitted with specifically designed cabs so the motive force can breathe clear air.
“Liebherr gives preparation for a protecting air flow system that filters particles (e.g. soot, asbestos) and gasses and moreover seals the cab,” says Walcher. The motive force can be protected by ballistic glass and a metal roof to forestall any sparks or splashes from severely injuring them. Liebherr’s L 550 to L 586 XPower wheel loaders may be specified for slag functions.
At Volvo CE, its slag loader vary, together with L150H, L180H, L220H, L260H and L350H fashions, may be fitted with a cab filtration system which circulates 90% of cab air by a filter. Whereas these options assist to enhance the motive force’s every day job, equipment producers additionally should equip slag handlers to deal with worst-case situation conditions. “A very powerful factor is operator security,” says Erich Kribs, GPE product supervisor at Volvo CE. “If the machine stops within the metal mill, we would like the operator to be within the machine for so long as potential.” Exiting the machine in these environments is prone to be extra harmful so Volvo has developed options for its slag handlers to permit the motive force to remain within the cab if the machine breaks down. The motive force is protected with a fireplace suppression system and an emergency limp residence mode, which permits the operator to maneuver the machine in first gear to offer them a possibility to maneuver to a safer place to get assist.
“If the operator shouldn’t be accessible or they get sick within the cab, we have now an engine shut down and parking brake launch on the rear,” says Kribs. This implies the car may be moved from the skin with out intervention from the motive force if they’re in problem.
Volvo CE additionally equips its slag loaders with a specialist towing level so one other machine can retrieve the wheel loader by positioning its bucket below the hitch and lifting the again of the car to tow it. Ordinarily, two autos could be manually hitched so this eliminates the necessity for an operator to exit their machine.
Within the occasion the motive force does must exit the car, Volvo CE gives an non-compulsory ladder which fits over the rear wheel arch. “Usually if there’s an issue with the machine within the metal mill, the entrance of the machine is standing within the sizzling space the place the fabric is. The operator can depart by way of this escape ladder to the rear of the car which is prone to be a safer space,” says Kribs.
Key diversifications
In comparison with a normal wheel loader, a number of parts on a slag handler have to be uprated for this excessive temperature atmosphere. “Because of the difficult working circumstances, the areas and parts which are notably uncovered to excessive circumstances have to be protected accordingly,” says as Walcher. “These embody hydraulic traces, piston rods, cables, underbody, electrical modules, central lubrication system and its traces, plastic components and discs. Sure areas of the machine are outfitted with an extra protecting perform. Parts which are manufactured from plastic in typical functions, for instance, are manufactured from metal on this case to resist the large warmth.”
A few of these extra protections embody metal mudguards, exterior metal mirrors, metal lamp holders, steel-braided hydraulic hoses, tipping cylinder piston rod safety and underbody guards. On high of this, some inner methods require the usage of different supplies. Kribs provides, “We’ve a unique, fire-resistant hydraulic oil so if a hose cracks, the hydraulic oil won’t begin to burn. Additionally, the grease inside is extra warmth resistant for working in these excessive temperature areas.”
“That is actually what we’d like in particular functions – working along with prospects to get their suggestions and discover the very best answer for everybody”
The challenges of testing
To verify these diversifications are appropriate for metal mills, equipment producers should object their machines to intensive excessive temperature testing. Because of the excessive traits of a metal mill, it’s arduous to copy these circumstances in a lab or synthetic setting. “To make sure that the wheel loaders are outfitted for the particular thermal circumstances, the machines had been examined in sensible use,” says Walcher. “Throughout this time, temperature measurements had been taken in several areas of the wheel loader. Liebherr developed acceptable protecting gear primarily based on the information collected.”
Equally, Volvo prefers to conduct real-world testing, as Kribs highlights, “You can’t check one thing like sizzling slag within the free area, it’s essential to go to a metal mill and discover anyone who helps you. We’re working with some key account prospects who’re blissful that we’re testing with them.”
Buyer suggestions is a vital a part of the event course of for brand spanking new attachments and components, Kribs explains, “We’re testing parts like slag dealing with buckets with prospects, we ship components or attachments, they check it after which say sure or no.” In addition to enter from the client, Volvo CE often conducts website visits to measure sure elements of the parts. For a slag bucket, testing focuses on temperature and stress measurements
to analyse longevity and any potential weaknesses within the bucket.
“It’s good to work collectively, that is actually what we’d like in all particular functions, to work along with the client to get their suggestions and discover out what’s the greatest answer for everybody. First, what’s greatest for the client, then what’s greatest for us,” says Kribs.
Whereas sizzling slag functions won’t be the commonest use for wheel loaders, these specialist diversifications are key in supporting metal mills and maintaining operators secure. In excessive temperature environments, the trade can not afford for a machine to be a fireplace threat or trigger unplanned downtime. Slag handles are a number of the most strong wheel loaders to allow mills to maintain working across the clock.
This text first appeared in iVT’s 2025 Off-highway Annual.
