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 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 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 atmosphere for the car and its operator. In consequence, many equipment producers supply 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 atmosphere, 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 presents 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 might make it unattainable 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 presents 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 also 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 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 means of a filter. Whereas these options assist to enhance the motive force’s each 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 inside the metal mill, we wish 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 motive 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 provide them a chance to maneuver to a safer place to get assist.
“If the operator just isn’t obtainable 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 car could be moved from the surface with out intervention from the motive 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 underneath the hitch and lifting the again of the car 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 motive force does must exit the car, Volvo CE presents 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 scorching space the place the fabric is. The operator can depart through this escape ladder to the rear of the car which is prone to be a safer space,” says Kribs.
Key diversifications
In comparison with a regular 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 can be notably uncovered to excessive situations have to be protected accordingly,” says as Walcher. “These embody 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 an extra protecting perform. Parts which can be made from plastic in standard functions, for instance, are made from metal on this case to resist 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 prime of this, some inside methods require the usage of different supplies. Kribs provides, “We have now a special, 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 prospects to get their suggestions and discover the most effective resolution for everybody”
The challenges of testing
To verify 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 laborious 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 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’t check one thing like scorching slag within the free subject, you could go to a metal mill and discover any person who helps you. We’re working with some key account prospects who’re completely happy that we’re testing with them.”
Buyer suggestions is an important a part of the event course of for brand spanking new attachments and components, Kribs explains, “We’re testing elements like slag dealing with buckets with prospects, we ship components or attachments, they check it after which say sure or no.” In addition to enter from the client, Volvo CE recurrently 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 functions, 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 functions won’t be the most typical use for wheel loaders, these specialist diversifications are key in supporting metal mills and holding operators secure. In excessive temperature environments, the trade can’t afford for a machine to be a fireplace danger or trigger unplanned downtime. Slag handles are among 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.
