“After the reduction of capital equipment expenditure in 2020, we indeed see a significant increase in demand for aluminium cast house equipment”, Michael Rockstroh, Managing Director of RIA Cast House Engineering GmbH

Michael Rockstroh has extensive experience in project management, equipment design, engineering services, and business development related to aluminium casthouse machinery with a focus on charging and skimming machines. He began working fulltime for Rackwitz Industrieanlagen GmbH (now RIA Cast House Engineering GmbH) in 2012, although assisted part-time in the workshop as far back as the year 2000. Michael has a B.Sc. and M. Sc. in Industrial Engineering, both from the University of Applied Sciences Jena in Germany.

AlCircle is pleased to interview Mr Rockstroh and know his aluminium market projection for 2021 and how his company is gearing up for the year.

AlCircle: What new developments are you planning for your Cast House equipment in 2021?

Mr Michael Rockstroh: After very interesting test results during our trials, we are excited that RiA is commissioning two additional In-Furnace Dross Processing (IFDP) units in North America in 2021. This major development will help the global movement towards the production of Greener Aluminium, as we will be reducing metal loss in the furnace and reducing the need for further transportation, tolling and processing of the remaining dross.

In addition, we have recently entered into an exclusive agreement with Fioscope GmbH to enable RiA to introducing Furnace Monitoring Systems using smart AI Cameras as a standalone product to further enhance safety and reduce carbon footprint in the Cast House.

AlCircle: Are you planning to come up with any new innovations in 2021 for further minimising dross generation in aluminium remelting process?

Mr Michael Rockstroh: Reduction of metal loss and increase in efficacy during the melting of aluminium are the two major goals for RiA. Therefore, we are constantly investing to improve and evolve existing solutions such as the camera based Autonomous Charging and Skimming and In-Furnace AI Camera based systems. We see that the accurate determination of the right timing for charging and skimming the furnace has a massive potential to reduce energy consumption, metal loss and CO₂-emissions. Minimising the frequency and duration of door openings is a key to this success.

AlCircle: How do you foresee the year 2021 for the global aluminium industry after the COVID-19 pandemic last year?

Mr Michael Rockstroh: The year 2020 was very challenging for all of us and the team at RiA did a great job to overcome difficulties such as international travel restrictions. This year we are seeing an extraordinary increase in activities. This indicates that there is an increase in demand for aluminium as well as confidence in our industry to invest and improve. We are optimistic for a brighter future.

AlCircle: Do you foresee an increase in demand for equipment at aluminium cast houses in 2021, in line with the rising production of aluminium?

Mr Michael Rockstroh: After the reduction of capital equipment expenditure in 2020, we indeed see a significant increase in demand for aluminium cast house equipment, with the demand appearing to be more than just a catch-up on the shortfall from last year. We are hopeful that 2021 could even exceed 2019 levels of business.

AlCircle: Do you think the use of artificial intelligence and digitisation will increase in the aluminium industry in 2021 after the pandemic we witnessed last year?

Mr Michael Rockstroh: The availability of work force and skilled labour that is willing to work in a Cast House environment is an issue, especially in western countries. Our response to that is automated equipment that is capable to make decisions using artificial intelligence. The pandemic gave this movement another push and companies now know more than ever that it is time to invest in smart solutions.

AlCircle: Are you planning to bring in more advanced digitisation to the Cast House in 2021?

Mr Michael Rockstroh: We first introduced In-Furnace Cameras over 7 years ago, initially visual only and quickly learnt that adding intelligence enhanced our traditional products of Furnace Charging and Furnace Skimming. We now see additional benefits from Image Processing beyond our equipment such as tracking refractory wear and damage and burner flame analysis etc. We know there are capabilities that we have not even imagined yet that we will be able to address as and when necessary.

AlCircle: Do you think the automation of the aluminium remelting process will ensure operator safety in 2021 and beyond?

Mr Michael Rockstroh: Our Machines have been capable of Automatic Operation, without operators onboard for a couple of years already. This has removed operators from hazardous locations at the high-risk stages in the melting cycle. Cameras on our machines now make them capable of intelligent decisions that were only previously possible by human beings. Cameras in the Furnace now mean it is unnecessary for any operator to open the furnace door to check on progress. Now it is not even necessary for the operator to look at an image on a screen in a pulpit, as the Smart Cameras make the decisions and let the operator know that the melt is ready for the next stage. It gives us great pride to know that every Smart Camera we install is making the working life of cast house operators safer.