To cut 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 a wide range of industries due to their adaptability for working with totally different supplies. In metal mill environments, wheel loaders present a vital position to maneuver scorching 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 automobile and its operator. Because of this, many equipment producers provide steel-mill particular wheel loaders to swimsuit this excessive software.
“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 secure and cozy 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 could be dusty and produce poisonous fumes that may make it inconceivable for operators to work safely for prolonged durations 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 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 forestall any sparks or splashes from severely 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 way of a filter. Whereas these options assist to enhance the motive force’s day by day job, equipment producers additionally should equip slag handlers to deal with worst-case situation conditions. “A very powerful 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 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 driving force is protected with a fireplace suppression system and an emergency limp dwelling mode, which permits the operator to maneuver the machine in first gear to present them a chance to maneuver to a safer place to get assist.
“If the operator shouldn’t be obtainable or they get sick within the cab, we’ve got an engine shut down and parking brake launch on the rear,” says Kribs. This implies the automobile could 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 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 motive force does have to exit the automobile, Volvo CE gives an non-obligatory ladder which matches 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 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 should be uprated for this excessive temperature setting. “Because of the difficult working circumstances, the areas and elements which can be significantly uncovered to excessive circumstances should be protected accordingly,” says as Walcher. “These embody hydraulic strains, piston rods, cables, underbody, electrical modules, central lubrication system and its strains, plastic elements and discs. Sure areas of the machine are outfitted with a further protecting operate. Parts which can be product of plastic in standard functions, for instance, are product of metal on this case to resist the large 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 the usage of various supplies. Kribs provides, “We’ve a unique, 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 functions – working along with clients to get their suggestions and discover the perfect resolution 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 laborious to copy these circumstances in a lab or synthetic setting. “To make sure that the wheel loaders are outfitted 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 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 subject, that you must go to a metal mill and discover anyone who helps you. We’re working with some key account clients who’re pleased 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 elements like slag dealing with buckets with clients, we ship elements or attachments, they take a look at it after which say sure or no.” In addition to enter from the shopper, Volvo CE commonly conducts web site visits to measure sure elements 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 functions, 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 scorching slag functions may not be the commonest use for wheel loaders, these specialist variations are key in supporting metal mills and holding operators secure. In excessive temperature environments, the business can not afford for a machine to be a fireplace threat or trigger unplanned downtime. Slag handles are a few 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.
