To cut 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 automobiles of their class
Wheel loaders are important machines throughout quite a lot of industries due to 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. Usually 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 atmosphere for the automobile 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 atmosphere, security and luxury are the highest priorities for Liebherr wheel loaders. Because of this, there are numerous tools choices that cut back fatigue and allow protected and comfy working,” explains Mark Walcher, product supervisor for XPower heavy tools 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 will make it unattainable for operators to work safely for prolonged intervals 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 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 motive force can be protected by ballistic glass and a metal roof to stop any sparks or splashes from significantly 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 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. “Crucial factor is operator security,” says Erich Kribs, GPE product supervisor at Volvo CE. “If the machine stops inside the metal mill, we wish the operator to be within the machine for so long as attainable.” 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 hearth 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 will not be obtainable or they get sick inside the cab, we now have 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 motive force if they’re in issue.
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 automobile to tow it. Ordinarily, two automobiles can 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 automobile, Volvo CE provides an elective ladder which works 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 automobile which is prone to be a safer space,” says Kribs.
Key variations
In comparison with an ordinary wheel loader, a number of elements on a slag handler have to be uprated for this excessive temperature atmosphere. “As a result of difficult working situations, the areas and elements which are notably uncovered to excessive situations 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 outfitted with a further protecting operate. Parts which are manufactured from plastic in standard purposes, for instance, are manufactured 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 inside methods require using different supplies. Kribs provides, “We’ve got a distinct, fire-resistant hydraulic oil so if a hose cracks, the hydraulic oil is not going to 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 most effective resolution for everybody”
The challenges of testing
To verify these variations are appropriate for metal mills, equipment producers should object their machines to intensive excessive temperature testing. As a result of excessive traits of a metal mill, it’s exhausting to duplicate these situations in a lab or synthetic setting. “To make sure that the wheel loaders are outfitted for the particular thermal situations, the machines had been examined in sensible use,” says Walcher. “Throughout this time, temperature measurements had been taken in numerous areas of the wheel loader. Liebherr developed applicable protecting tools based mostly on the info collected.”
Equally, Volvo prefers to conduct real-world testing, as Kribs highlights, “You can not take a look at one thing like sizzling slag within the free subject, you might want to 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 an important a part of the event course of for brand new attachments and components, Kribs explains, “We’re testing elements like slag dealing with buckets with clients, we ship components or attachments, they take a look at it after which say sure or no.” In addition to enter from the shopper, Volvo CE frequently conducts web site visits to measure sure facets of the elements. 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 shopper to get their suggestions and discover out what’s the greatest resolution for everybody. First, what’s greatest for the shopper, then what’s greatest for us,” says Kribs.
Whereas sizzling slag purposes won’t be the most typical use for wheel loaders, these specialist variations are key in supporting metal mills and protecting operators protected. In excessive temperature environments, the trade can’t afford for a machine to be a hearth 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.
