32 Ton QD Heavy-Duty Overhead Crane Case Study in Indonesia Nickel Smelting Plant

Following Indonesia’s raw ore export restrictions, local smelting capacity has significantly increased. A client built a new converter workshop in the Sulawesi Industrial Park. The project requires overhead cranes with high starting frequencies (S4 duty). They must handle molten iron filling, slag pot moving, and maintenance. HSCRANE provided multiple customized QD type heavy-duty overhead crane.

Overhead Crane Core Technical Parameters

The overhead crane selection exceeds standard industrial specs for heavy loads. This design enhances the fatigue strength of the mechanical structure.

Engineering Solutions & Technical Advantages

Structural Reinforcement Design

The design considers continuous impact loads in the smelting workshop. The main girders use Q355B high-strength carbon structural steel. All steel surfaces undergo shot blasting to reach Sa2.5 grade.

Every butt weld undergoes 100% Ultrasonic Testing (UT) and Radiographic Testing (RT). This ensures no structural fatigue cracks during long-term heavy-load cycles.

High-Temperature Protection System

The Sulawesi climate is hot, and workshop heat radiation is intense. HSCRANE overhead crane utilizes multiple protections:

• Heat Insulation Layer: Radiation heat shields are installed under main girders. They reduce direct heat radiation from molten steel.
• High-Temperature Cables: The entire crane uses silicone rubber insulated fire-resistant cables. These operate continuously at 180°C.
• Split Air-Conditioning: Cabin and electrical rooms use independent cooling systems. These ensure components and operators stay at optimal temperatures.

Smelting-Specific Electrical System

• Redundant Safety Control: Hoisting mechanisms feature double brakes for service and safety. If one brake fails, the other safely locks the hook.
• PLC & Touchscreen Monitoring: Systems monitor motor current, lifting height, and overload status. Self-diagnostics significantly reduce troubleshooting time for local Indonesian technicians.
• Heavy-Duty Anti-Sway: Electrical damping algorithms reduce hook inertia and swaying. This technology improves hoisting precision during frequent operations.

Corrosion Treatment for Southeast Asian Climates

High humidity and sulfur gases require specialized coating. Metal surfaces use a three-layer system: epoxy zinc-rich primer, epoxy micaceous iron oxide intermediate, and polyurethane topcoat. The total film thickness exceeds 160μm. This provides excellent resistance to heat, humidity, and salt spray.

Delivery and Application Performance

After arriving at the Indonesian port, HSCRANE engineers guided onsite assembly and load testing. The equipment now operates on 24-hour shifts.

Customer feedback shows that HSCRANE QD overhead cranes offer superior girder deflection control. They outperform similar local models under high-temperature, full-load conditions. The motor temperature rise consistently stays within safe ranges. This performance ensures the continuous operation of the smelting production line.

HSCRANE’s success in this Indonesian nickel-iron project demonstrates our deep customization capabilities. We adapt to various global climates and industries like smelting, chemicals, and mining. By utilizing FEM and ISO standards, we provide reliable heavy material handling equipment for Southeast Asian industrialization.