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Saturday, March 15, 2025

FEATURE: How can OEMs maximise security for operators transferring molten slag?


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 automobiles of their class 

Wheel loaders are important machines throughout quite a lot of industries because of 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. 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 surroundings for the automobile and its operator. Because of this, many equipment producers provide 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 tools choices that scale back fatigue and allow protected and comfy working,” explains Mark Walcher, product supervisor for XPower heavy tools 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 may 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 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 driving force can also be protected by ballistic glass and a metal roof to stop any sparks or splashes from critically 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 each 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 within 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 motive 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 just isn’t out there or they get sick within the cab, we have now an engine shut down and parking brake launch on the rear,” says Kribs. This implies the automobile 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 automobile to tow it. Ordinarily, two automobiles could 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 presents 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 scorching space the place the fabric is. The operator can depart through this escape ladder to the rear of the automobile which is more likely to be a safer space,” says Kribs.

ABOVE: A fireplace-resistant hydraulic oil has been used for Volvo CE’s slag loader vary

Key diversifications

In comparison with an ordinary wheel loader, a number of elements on a slag handler should be uprated for this excessive temperature surroundings. “As a result of difficult working circumstances, the areas and elements which might be significantly uncovered to excessive circumstances should 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 an extra protecting operate. Parts which might be made from plastic in typical functions, for instance, are made from metal on this case to resist the big 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 inner programs require using various supplies. Kribs provides, “We now have 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 perfect 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 exhausting to duplicate these circumstances in a lab or synthetic setting. “To make sure that the wheel loaders are outfitted for the particular thermal circumstances, 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 scorching slag within the free subject, you have to go to a metal mill and discover any individual who helps you. We’re working with some key account prospects 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 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 shopper, Volvo CE commonly 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 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 won’t be the most typical use for wheel loaders, these specialist diversifications are key in supporting metal mills and protecting operators protected. In excessive temperature environments, the business can not afford for a machine to be a hearth danger or trigger unplanned downtime. Slag handles are a few 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.

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