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 a vital 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 may 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. Because of this, 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. 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 affords 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 may make it not possible 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 driving force can breathe clear air.
“Liebherr affords 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 also 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 may be specified for slag purposes.
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 way of a filter. Whereas these options assist to enhance the driving force’s day by day job, equipment producers additionally should equip slag handlers to deal with worst-case state of affairs conditions. “A very powerful 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 doable.” 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 house mode, which permits the operator to maneuver the machine in first gear to provide them a possibility to maneuver to a safer place to get assist.
“If the operator isn’t out there or they get sick inside the cab, we’ve got an engine shut down and parking brake launch on the rear,” says Kribs. This implies the automobile may 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 below the hitch and lifting the again of the automobile 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 driving force does have to exit the automobile, Volvo CE affords 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 automobile which is more likely to be a safer space,” says Kribs.
Key diversifications
In comparison with a typical wheel loader, a number of parts on a slag handler should be uprated for this excessive temperature surroundings. “As a result of difficult working situations, the areas and parts which might be notably uncovered to excessive situations should be protected accordingly,” says as Walcher. “These embody 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 an extra protecting operate. Elements which might be manufactured from plastic in typical purposes, for instance, are manufactured from metal on this case to resist the big 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 techniques require using different supplies. Kribs provides, “We’ve a unique, 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 perfect answer 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. As a result of excessive traits of a metal mill, it’s onerous 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 have been examined in sensible use,” says Walcher. “Throughout this time, temperature measurements have been taken in numerous areas of the wheel loader. Liebherr developed applicable protecting gear based mostly on the info collected.”
Equally, Volvo prefers to conduct real-world testing, as Kribs highlights, “You can’t check one thing like sizzling slag within the free discipline, it is advisable go to a metal mill and discover anyone who helps you. We’re working with some key account clients who’re completely satisfied that we’re testing with them.”
Buyer suggestions is a vital a part of the event course of for brand new attachments and elements, Kribs explains, “We’re testing parts like slag dealing with buckets with clients, we ship elements or attachments, they check it after which say sure or no.” In addition to enter from the shopper, Volvo CE repeatedly conducts web site 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 purposes, to work along with the shopper to get their suggestions and discover out what’s the greatest answer for everybody. First, what’s greatest for the shopper, then what’s greatest for us,” says Kribs.
Whereas sizzling slag purposes may not be the most typical use for wheel loaders, these specialist diversifications are key in supporting metal mills and preserving operators protected. In excessive temperature environments, the trade can’t afford for a machine to be a hearth danger or trigger unplanned downtime. Slag handles are a number of 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.
