To scale back the dangers of transferring 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 a vital 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 might 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 scale 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 might be dusty and produce poisonous fumes that will make it unattainable for operators to work safely for prolonged durations of time. To fight this, wheel loaders for decent slag dealing with are outfitted with specifically designed cabs so the driving 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 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 might be specified for slag purposes.
At Volvo CE, its slag loader vary, together with L150H, L180H, L220H, L260H and L350H fashions, might 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 every 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 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 driving force to remain within the cab if the machine breaks down. The driving 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 provide them a chance to maneuver to a safer place to get assist.
“If the operator isn’t 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 car might be moved from the surface 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 car 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 have to exit the car, Volvo CE gives an optionally available 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 depart by way of this escape ladder to the rear of the car which is prone to be a safer space,” says Kribs.
Key variations
In comparison with a typical wheel loader, a number of elements on a slag handler should be uprated for this excessive temperature setting. “As a result of difficult working situations, the areas and elements which can be notably uncovered to excessive situations should be protected accordingly,” says as Walcher. “These embody hydraulic strains, piston rods, cables, underbody, electrical modules, central lubrication system and its strains, plastic components and discs. Sure areas of the machine are outfitted with an extra protecting perform. Elements which can be made from plastic in standard purposes, for instance, are made from metal on this case to face up to the large warmth.”
A few of these further 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 programs require the usage of different supplies. Kribs provides, “We’ve got 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 prospects 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 in depth excessive temperature testing. As a result of excessive traits of a metal mill, it’s onerous 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 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 acceptable protecting gear primarily based 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 scorching slag within the free area, it is advisable go to a metal mill and discover anyone who helps you. We’re working with some key account prospects who’re glad 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 elements like slag dealing with buckets with prospects, we ship components 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 website visits to measure sure features 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 client to get their suggestions and discover out what’s the finest resolution for everybody. First, what’s finest for the client, then what’s finest for us,” says Kribs.
Whereas scorching slag purposes may not be the commonest use for wheel loaders, these specialist variations are key in supporting metal mills and retaining operators secure. In excessive temperature environments, the trade can’t afford for a machine to be a fireplace threat 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.
