In zinc electrowinning (EW) systems, aluminum cathodes are central to maintaining stable current flow and deposit quality. To ensure consistent performance, each cathode must pass a series of quality checks before shipment.
This article outlines how PRS inspects a batch of 450 finished aluminum cathodes, focusing on two critical areas: appearance and dimensional accuracy.
Appearance Inspection
Each aluminum cathode is carefully checked for surface finish, structural integrity, and welding quality before proceeding to dimensional verification. In this batch of 450 cathodes, PRS maintained a high standard of consistency—no visible defects were found, and all units met the required appearance criteria for zinc electrowinning use.
Appearance Inspection Checklist
Inspection Item | What We Look For |
Surface Finish | Clean surface with no dents, scratches, oil, or residue |
Welding Seams | Smooth, continuous welds with no gaps or splatter |
Plate Straightness | No visible bending or warping of the aluminum plate |
Beam & Lug Alignment | Conductive beam and lifting lug properly aligned and level |
Visual Defects | No burrs, rust, oxidation, or sharp edges |
All cathodes are placed on steel racks in an orderly manner, which supports both inspection visibility and safe packing.
Dimensional Inspection
Dimensional accuracy is essential to ensure proper installation and safe operation. Measurements are divided into two key parts:
1. Conductive Assembly Inspection
The conductive beam section includes several critical components that must be dimensionally accurate and structurally sound. This includes the main conductive beam itself, the contact copper block for current transmission, and the lifting lug for safe crane operation. Each part is measured carefully to ensure compliance with the design drawing and operational safety standards.
- Conductive Beam
Length of the Conductive Beam – Detail
Length of the Conductive Beam
Height of the Conductive Beam
Thickness of the Conductive Bean
- Contact Copper Block
Thickness of the Single Piece of Contact Copper Block
Length of the Contact Copper Block
Height of the Conductive Beam
- Lifting Lug
Detailed Dimension of Lifting Lug – 2
Detailed Dimension of Lifting Lug – 1
Detailed Dimension of Lifting Lug – 3
Distance between 2 Lifting Lugs – Detail
2. Aluminum Plate Body Inspection
The aluminum plate defines the effective deposition area and must meet strict dimensional requirements for stable zinc electrowinning performance. At PRS, we measure each cathode plate for height, effective length, thickness, and the distance from the welding line to the designed liquid level. The following photos document actual measurement procedures carried out during the inspection.
Height of the Al Plate
(Bottom to the Welding Line) – Detail
Height of the Al Plate
(Bottom to the Welding Line)
Length of the Edge Strips – Detail
Length of the Edge Strips
Measurement – Welding Line to Liquid Level
Measurement – Welding Line to Liquid Level – Detail
Thickness of the Edge Strip
Thickness of the Al Plate
Width of the Al Plate – Detail
Width of the Al Plate
Width of the Al Plate Including Edge Strips – Detail
Width of the Al Plate Including Edge Strips
Conclusion
Inspecting aluminum cathodes is not just a step in the shipping process—it’s a critical part of ensuring performance, reliability, and client satisfaction.
By focusing on both appearance and precise dimensions, PRS guarantees that every cathode delivered is ready for immediate use in zinc EW operations.
Through structured inspection and full traceability, we help our clients operate with confidence—plate by plate, batch by batch.
