1. Work Experience and Education
• Dow Chemical Int. Private Limited, Pune [From Mar 07]
– Senior Research Engineer, Solid Processing, EPS
• Ansys Software Pvt. Limited [Apr 06 – Feb 07]
– Senior Technical Support, CFD (CFX Software)
• Ph.D. [2002-2006]
– I.I.T. Bombay, Mumbai/ N.C.L., Pune
– Dissertation - Modeling of Rotary Cement Kilns
• Research Assistant [2001-2002]
– Delft University of Technology, The Netherlands
• M. Tech., Chemical Engineering [IIT Madras, Chennai]
• B. E., Chemical Engineering [Mumbai University]

2. Summary
• Practicing mathematical modeling tools like Computational Fluid Dynamics
(CFD), Discrete Element Modeling (DEM) and lower order models/reactor
engineering modeling using FORTRAN subroutines to harness
performance improvement in process industry.
• Conversant with commercial CFD codes/meshing tools – Fluent, CFX,
StarCCM+, Star-CD, ICEM-CFD and Gambit 2.0.
• Conversant with commercial DEM code PFC3D of ITASCA and Star-CD of
CD-Adapco.
• Conversant with commercial software “GeoDict -2009” used for modeling
of flow through fibrous material and ImageJ, a image processing tool.
• Sound knowledge of FORTRAN Programming. Conversant with Statistical
tools (JMP 8.0) and introduced to innovation tools (TRIZ)
• 1 Monograph, 5 Journal Publications, several conference presentations

3. Coupled CFD-DEM Model for Two Phase Flows*
Developed two phase modeling capability using coupled CFD-DEM methodology and validated it with
literature data
Tools used: Coupled DEM-CFD module from Star-CD tool of CD-Adapco.
Model Validation
400 350
350 Experiments
Experiments
Simulations
300 Simulation
300
250
∆P, Pa/m
∆ P, Pa/m
200
Modeled gas-solid flows through horizontal pipes 250
150
Identified flow regimes for varying velocities 100 200
Simulated effect of various micro-parameters 50
0
150
Validated model for pressure drop and velocity 0 10 20
Velocity (m/s)
30 40
0 0.5 1 1.5 2
Solids mass flow/air mass flow
measurements
5 5 5
5
Solids loading: 743 kg/h
Solids loading: 743 kg/h
Solids loading: 251 kg/h Solids loading: 251 kg/h
Experiments Experiments Experiments
Up = Uf 4 Experiments 4 Up=Uf 4 Rest. Coeff.=0.65
4
Up = 0.5Uf Rest. Coeff. = 0.65 Up = 0.5Uf
Rest. Coeff.=0.8
Rest. Coeff. = 0.8
∆P mbar/m
3 3
∆ P mbar/m
3 3
∆P mbar/m
P mbar/m
2 2 2
2
1 1 1
1
0 0 0
0
0 5 10 15 20 25 30 35 0 5 10 15 20 25 30 35
0 5 10 15 20 25 30 35 0 5 10 15 20 25 30 35 Uf, m/s
Uf, m/s Uf , m/s Uf, m/s
*Prasad DVN and Mujumdar K.S., Modeling two phase conveying flows using coupled DEM-CFD, presented at APT-2009.

4. Optimizing Ball Mill Operations using DEM*
Developed a Discrete Element Model for capturing motion of grinding media in ball mills. Predicted power
draw of mill based on particle motion. Analyzed collision intensity and frequency of the grinding media for
predicting optimum mill operation
Tools used: PFC3D from Itasca
22 rpm
Developed DEM Simulations consider grinding
media only Plant mill
Model in PFC3D
Application on
Application on
pilot & production
Experimental mill
mill
Pilot mill Experiments* Simulation
Experimental mill
Optimize mill rpm Optimize particle diameter
Modeled motion of grinding media in ball 1 500 40000
35000
N o r m a liz e d P o w e r d r a w ( - )
mills for particle motion and mill power draw 0.8 400
M a x im u m c o n ta c t fo rc e (N )
30000
M a x im u m In te n s ity ( N )
25000
Reproduced flow regimes for varying mill 0.6
20% Fill
300
20000
30 % Fill
rpm using developed model 0.4
40 % Fill
200 15000
50 % Fill 10000
Identified optimum operating conditions to 0.2
60 % Fill
100
5000
improve performance of operating trains 0
20 30 40 50 60 70 80 90 100
0
0.01 0.015 0.02 0.025 0.03 0.035 0.04 0.045
0
0.05
Particle diameter (m)
Percentage critical speed (%)
*Theuerkauf J. and Mujumdar K. S., Optimization and scale up of ball mills using discrete element simulations, Presented at AIChE meeting, 2008.

5. Modeling of Rotary Cement Kiln
• Rotary Cement Kilns Coating
Rotating kiln
– Gas phase/coal combustion Exhaust gases Secondary Air
– Clinkerization reactions Entrainment Radiation
Coal +
Primary Air
– Solid Flow in bed
Melt
Clinker
– Coating/Melt formation Partially Calcined
Raw Meal
Clinker Reactions
Flame
– Mass transfer/Heat Transfer
Figure 1: Rotary cement kiln schematic
RoCKS Reaction Engineering Model
Pseudo-homogeneous bed CFD Model
region/ variation of bed Coupling of bed and freeboard
height/ plug flow/ 1D coal region, Eulerian-Lagrangian
combustion model with approach for the freeboard,
inputs from CFD simulations, Eulerian approach for the bed,
solids melting & coating details of burner configuration,
formation turbulence, radiation
Overall Plan
Modeling of Rotary Cement Kiln, Ph. D. Thesis, I.I.T Bombay, 2007

6. Reaction Engineering based Model
0.2
0.18
Qs = 246 kg/hr
Qs = 350 kg/hr
Evaluate Performance
Qs = 480 kg/hr
0.16
Kramers Model
Kramers Model
• Number of Pre-heaters
Kramers Model
0.14
• Percentage Calcination
0.12
• Kiln RPM
Heigth (m)
0.1
0.08
• Kiln Tilt
0.06
0.04
• Grate Speed
0.02
• Raw Meal Flow Rate
• Gas Flow Rate
0
0 1 2 3 4 5 6
Norm a liz e d Kiln L e n gth (-)
Watkinson and Brimacombe (1982) Kramers and Croockewit (1952) • Oxygen Enrichment
Calcination Experiments Bed Height Experiments • Coal Composition
60 800
160 0.25
55
Energy recovered, kcal/kg clinker
700 0.23
150
50
Energy Consumption, kcal/kg
0.21
Exit air temperature, K
Percentage fill at solid inlet
600
45 0.19
140
0.17
clinker,
40 500
130 0.15
35
400 Hot Air Air 0.13
120
30 Energy recovered Hot Shell 0.11
Exit air temperature 300
25 0.09
110
20 200
Concept of secondary shell 0.07
0 10 20 30 40 50 Engin and Ari (2005) 100 0.05
20 30 40 50 60 70
Mass flow rate air, kg/s
Solid feed rate, kg/s
Modeling of Rotary Cement Kiln, Ph. D. Thesis, I.I.T Bombay, 2007

7. CFD MODEL
Heat Loss
(Radiation + convection)
CO2 from Calcination
Reaction in bed Conduction heat
transfer (walls)
Temperature
Freeboard (bc* to freeboard)
Heat Flux
(bc* to bed) Bed
common surface
(bed/freeboard) *boundary condition
Developed Efficient Coupling Strategies Computational Grid, Gambit
to Model Cement Kilns
Temperature, K ( = 2345 K; = 300 K)
Axial /Swirl Ratio = 2 (C3S = 0.5)
(b) DPM burn out, kg/s ( = 1.24 x 10-4; = 0) Axial /Swirl Ratio = 1 (C3S = 0.45)
Model Predictions, Fluent 6.2.16 Burner Numerical Experiments
Modeling of Rotary Cement Kiln, Ph. D. Thesis, I.I.T Bombay, 2007

8. MONOGRAPH