Work

National Council for Cement and Building Materials (NCCBM) (a.k.a. Cement Research Institute of India (CRI)) is an apex body oversees technical and educational needs of cement industry. I was appointed as deputy manager (process) in Centre for Mining, Environment Plant Engineering & Operation (CME) and the period of employment was 2009-2014. I have visited more than 25 cement plants on various projects. Some of them with direct involvement on different projects were:

1. CFD simulation of improving the performance of air pollution control equipment’s in cement industry using commercial CFD solver FLUENT. (project cost Rupees 80 lakhs).

2. Technical feasibility study of co-firing spent wash from distilleries in cement rotary kiln. (project cost Rupees 20 lakhs).

3. Thermal energy audit studies in pyro-processing system of four cement plants. (project cost Rupees 10 lakhs).

4. Conducted baseline energy audit for cement plants to establish specific energy consumption (SEC). Based on this specific targets will be given to improve energy efficiency in cement plants under Perform, Achieve and Trade (PAT) Scheme of Bureau of Energy Efficiency (BEE). (project cost Rupees 16 lakhs).

Supervised the cement process simulator training cum programs, conducted training programs on alternate fuels in cement industry, grinding systems and pyro-system technologies, preparation of proposals for research and development (R&D) and sponsored projects, and involved on international organization of standards (ISO) internal audits. In addition, I was in-charge of process related instruments that were used to measure onsite process parameters. As faculty, delivered lectures on thermal energy audit in cement plants, combustion process in kiln, and different types of grinding technology in cement industry. Attended international seminars organized by Confederation of Indian Industry (CII) like Green Cementech, Energy Efficiency Summit and onsite workshops on alternate fuels co-processing in cement industry at Associated Cement Companies Limited (ACC Ltd.,) (Holcim Group, Switzerland) Wadi, Karnataka, India. Hands on practical experience on stacks/chimneys and environmental concerns for asserting the pollution emission levels. I have visited on the same to glass factories, industrial fans (M/s Reitz company) and cement industries.

Expertise:

†Expertise on cement processing technology and its optimization. With considerations of following:

a.     Upto 10000 tonnes per day plants. Pyro-processing technologies of FLSmidth, KHD, Polysius etc.

b.     Training expert on advanced cement process simulators or in general simulators.

c.    Waste alternate fuels in cement industry. Quality considerations of raw meal, coal, clinker and other additives. Environmental concerns on particulate emissions.

d.     Grinding technology in cement industry for e.g. ball mill, roller mill and roller press-ball mill with separator technologies.

e.     Central control room know-how and advanced quality testing technologies.

†Expertise on CFD simulations.

a.     Process modelling and simulation. Problems related to multiphase flow with multiphysics. Reactors - Rotary kiln-calciner, cyclones, electrostatic precipitator and baghouse.

†Expertise on chemical or process engineering operations for e.g. filtration, distillation, batch reactors, catalysts, water treatment or desalination plants, incinerators and effluent treatment. Practical/technical know-how on pharmaceutical plants.

Supervised undergraduate and postgraduate students, as well as process engineers, company executives, international visitors & production managers of cement and related manufacture.

Key software expertise: COMSOL Multiphysics, Ansys Fluent, High Performance Computing (HPC) on a cluster.

†The specific expertise’s is also applicable to oil & gas, petrochemical complexes and allied industries.