To cut back the dangers of shifting 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 due to their adaptability for working with completely different supplies. In metal mill environments, wheel loaders present an important function to maneuver sizzling slag. These impurities from metal making are faraway from the furnace for reuse or repurposing into aggregates. Usually likened to lava, this molten slag could be discovered at excessive temperatures as much as round 1,200°C presenting a harmful and high-risk working setting for the car and its operator. Because of this, many equipment producers supply steel-mill particular wheel loaders to swimsuit this excessive utility.
“At Liebherr, buyer satisfaction and security are on the forefront of all options. For the work on this setting, security and luxury are the highest priorities for Liebherr wheel loaders. For that reason, there are numerous gear choices that cut back fatigue and allow protected and comfy working,” explains Mark Walcher, product supervisor for XPower heavy gear at Liebherr.
“Liebherr provides 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 could be dusty and produce poisonous fumes that will make it inconceivable for operators to work safely for prolonged intervals of time. To fight this, wheel loaders for decent slag dealing with are outfitted with specifically designed cabs so the motive force can breathe clear air.
“Liebherr provides preparation for a protecting air flow system that filters particles (e.g. soot, asbestos) and gasses and moreover seals the cab,” says Walcher. The driving force can be protected by ballistic glass and a metal roof to forestall any sparks or splashes from critically injuring them. Liebherr’s L 550 to L 586 XPower wheel loaders could be specified for slag functions.
At Volvo CE, its slag loader vary, together with L150H, L180H, L220H, L260H and L350H fashions, could be fitted with a cab filtration system which circulates 90% of cab air by means of a filter. Whereas these options assist to enhance the motive force’s each day job, equipment producers additionally should equip slag handlers to deal with worst-case situation conditions. “Crucial factor is operator security,” says Erich Kribs, GPE product supervisor at Volvo CE. “If the machine stops inside 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 more likely 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 driving force is protected with a hearth suppression system and an emergency limp house mode, which permits the operator to maneuver the machine in first gear to present them a possibility to maneuver to a safer place to get assist.
“If the operator is just not obtainable or they get sick inside the cab, we have now an engine shut down and parking brake launch on the rear,” says Kribs. This implies the car could be moved from the surface 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 underneath 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 have to exit the car, Volvo CE provides an non-obligatory 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 go away by way of this escape ladder to the rear of the car which is more likely to be a safer space,” says Kribs.
Key diversifications
In comparison with a normal wheel loader, a number of parts on a slag handler should be uprated for this excessive temperature setting. “Because of the difficult working situations, the areas and parts which might be notably uncovered to excessive situations should be protected accordingly,” says as Walcher. “These embrace hydraulic traces, piston rods, cables, underbody, electrical modules, central lubrication system and its traces, plastic elements and discs. Sure areas of the machine are outfitted with a further protecting perform. Elements which might be product of plastic in typical functions, for instance, are product of metal on this case to resist the big warmth.”
A few of these further protections embrace 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 programs require using different supplies. Kribs provides, “We now have a distinct, 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 want in particular functions – working along with prospects to get their suggestions and discover the most effective resolution for everybody”
The challenges of testing
To ensure 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 situations in a lab or synthetic setting. “To make sure that the wheel loaders are outfitted for the particular thermal situations, the machines have been examined in sensible use,” says Walcher. “Throughout this time, temperature measurements have been taken in several areas of the wheel loader. Liebherr developed acceptable protecting gear based mostly on the info collected.”
Equally, Volvo prefers to conduct real-world testing, as Kribs highlights, “You can’t take a look at one thing like sizzling slag within the free subject, it’s good to go to a metal mill and discover any individual 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 elements, Kribs explains, “We’re testing parts like slag dealing with buckets with prospects, we ship elements or attachments, they take a look at it after which say sure or no.” In addition to enter from the client, Volvo CE commonly conducts web site visits to measure sure features 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 want in all particular functions, to work along with the client to get their suggestions and discover out what’s the greatest resolution for everybody. First, what’s greatest for the client, then what’s greatest for us,” says Kribs.
Whereas sizzling slag functions may not be the commonest use for wheel loaders, these specialist diversifications are key in supporting metal mills and retaining operators protected. In excessive temperature environments, the business can’t afford for a machine to be a hearth danger or trigger unplanned downtime. Slag handles are among the most sturdy wheel loaders to allow mills to maintain working across the clock.
This text first appeared in iVT’s 2025 Off-highway Annual.
