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Traditional carbon anodeCarbon anode qualityAnode quality controlQuality control relies on destructive sampling and subjective visual inspectionVisual inspection, failing to detect critical internal defects that can impact aluminum smeltingAluminum smelting efficiency. This study presents the first comprehensive industrial validation of Specific Electrical Resistance MeasurementMeasurements of AnodesAnode (SERMA), a mobile non-destructive testing system generating detailed 3D electrical resistivity maps of both green and baked anodesAnode. A one-year campaign at Emirates Global AluminiumAluminium tested 4,491 anodesAnode, demonstrating robust measurementMeasurements system capability and revealing internal defects invisible to conventional surface inspection. Analysis of over 2,000 green anodesAnode identified distinct spatial resistivity linked to upstream process parametersProcess parameter including vibrating time and kneader energyEnergy. Preliminary green-to-baked correlation studies showed promising relationships between green anodeAnode resistivity and final baked qualityQuality, with potential applications in predictive quality controlQuality control and strategic bakingBaking pit placement. This work presents SERMA’s capability to support anodeAnode manufacturing transformation from reactive inspection to proactive, data-driven process optimizationOptimization.

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Industrial 3D Electrical Resistance Mapping for Anode Quality Control

  • 会议论文

  • 发表日期：

    2026年

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  • Edouard Mofor,
  • Pentakota Rao,
  • Rawa Ba Raheem,
  • Amer Al Marzooqi,
  • Duygu Kocaefe,
  • Yasar Kocaefe,
  • Jean-Francois Desmeules

摘要

Traditional carbon anodeCarbon anode qualityAnode quality controlQuality control relies on destructive sampling and subjective visual inspectionVisual inspection, failing to detect critical internal defects that can impact aluminum smeltingAluminum smelting efficiency. This study presents the first comprehensive industrial validation of Specific Electrical Resistance MeasurementMeasurements of AnodesAnode (SERMA), a mobile non-destructive testing system generating detailed 3D electrical resistivity maps of both green and baked anodesAnode. A one-year campaign at Emirates Global AluminiumAluminium tested 4,491 anodesAnode, demonstrating robust measurementMeasurements system capability and revealing internal defects invisible to conventional surface inspection. Analysis of over 2,000 green anodesAnode identified distinct spatial resistivity linked to upstream process parametersProcess parameter including vibrating time and kneader energyEnergy. Preliminary green-to-baked correlation studies showed promising relationships between green anodeAnode resistivity and final baked qualityQuality, with potential applications in predictive quality controlQuality control and strategic bakingBaking pit placement. This work presents SERMA’s capability to support anodeAnode manufacturing transformation from reactive inspection to proactive, data-driven process optimizationOptimization.