To scale back the dangers of shifting scorching 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 scorching slag. These impurities from metal making are faraway from the furnace for reuse or repurposing into aggregates. Typically likened to lava, this molten slag will be discovered at excessive temperatures as much as round 1,200°C presenting a harmful and high-risk working surroundings for the automobile and its operator. Consequently, many equipment producers supply steel-mill particular wheel loaders to go well with this excessive software.
“At Liebherr, buyer satisfaction and security are on the forefront of all options. For the work on this surroundings, 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 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 will be dusty and produce poisonous fumes that might make it not possible for operators to work safely for prolonged intervals of time. To fight this, wheel loaders for decent slag dealing with are geared up with specifically designed cabs so the driving 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 stop any sparks or splashes from severely injuring them. Liebherr’s L 550 to L 586 XPower wheel loaders will be specified for slag purposes.
At Volvo CE, its slag loader vary, together with L150H, L180H, L220H, L260H and L350H fashions, will 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 driving 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 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 more likely to be extra harmful so Volvo has developed options for its slag handlers to permit the driving 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 dwelling mode, which permits the operator to maneuver the machine in first gear to provide them a chance to maneuver to a safer place to get assist.
“If the operator shouldn’t be out there 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 automobile will be moved from the skin with out intervention from the driving 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 beneath the hitch and lifting the again of the automobile to tow it. Ordinarily, two autos can be manually hitched so this eliminates the necessity for an operator to exit their machine.
Within the occasion the driving force does must exit the automobile, Volvo CE provides 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 scorching space the place the fabric is. The operator can go away by way of this escape ladder to the rear of the automobile which is more likely to be a safer space,” says Kribs.
Key variations
In comparison with an ordinary wheel loader, a number of parts on a slag handler have to be uprated for this excessive temperature surroundings. “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 embrace hydraulic traces, piston rods, cables, underbody, electrical modules, central lubrication system and its traces, plastic components and discs. Sure areas of the machine are geared up with a further protecting operate. Elements which are fabricated from plastic in typical purposes, for instance, are fabricated from metal on this case to face up to the large 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 methods require using different supplies. Kribs provides, “We have now 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’d like in particular purposes – working along with clients to get their suggestions and discover the perfect answer for everybody”
The challenges of testing
To ensure these variations are appropriate for metal mills, equipment producers should object their machines to in depth excessive temperature testing. Because of the excessive traits of a metal mill, it’s exhausting to duplicate these circumstances in a lab or synthetic setting. “To make sure that the wheel loaders are geared up for the particular thermal circumstances, 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 applicable protecting gear based mostly on the information collected.”
Equally, Volvo prefers to conduct real-world testing, as Kribs highlights, “You can not check one thing like scorching slag within the free subject, that you must go to a metal mill and discover any individual who helps you. We’re working with some key account clients who’re completely happy that we’re testing with them.”
Buyer suggestions is a vital a part of the event course of for brand new attachments and components, Kribs explains, “We’re testing parts like slag dealing with buckets with clients, we ship components or attachments, they check it after which say sure or no.” In addition to enter from the client, Volvo CE commonly conducts website visits to measure sure points 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 purposes, to work along with the client to get their suggestions and discover out what’s the finest answer for everybody. First, what’s finest for the client, then what’s finest for us,” says Kribs.
Whereas scorching slag purposes won’t be the commonest use for wheel loaders, these specialist variations are key in supporting metal mills and conserving operators secure. In excessive temperature environments, the business can’t afford for a machine to be a hearth danger or trigger unplanned downtime. Slag handles are a few 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.
