The Centre of Excellence Metallurgical Engineering and Materials Science, in Steel. Technology (Cobst), Department of IT Bombay has the largest number of faculty members working in the area process metallurgy/modeling among all other institutions in the country.This page gives a bird's eye view of the various projects carried out in the area of process modeling for the iron and steel sector as below
In collaboration with Lulea University of Technology, Sweden A model to help in predicting the quality of the pellet as a function of excursion the pellet makes in the induration reactor A 2-D Model to predict the inner state of blast furnace and can be used to study innovations such as tuyere injections and shaft injections.
A simulator to help in predicting the temperature and gas composition profile along the length and height of the straight grate process
A model to predict the maximum amount of Natural Gas, Hydrogen, etc. that can be injected into the blast furnace for different grades of iron ore pellets and sinter.
Overall plant Simulation to aid decision making towards energy efficiency, emissions and sustainability
Predicting the static hold up of slag in the bosh zone which affects the blast furnace productivity
A 2-D Model to predict the inner state of blast furnace and can be used to study innovations such as tuyere injections and shaft injections
Machine Learning Model developed based on past data and operator experience to predict the occurrence of channelling in advance and suggest corrective action to the operator.
Capable of simulating reduction, carburization using CO/H2/CH4 gases in any proportion – Needed tool to aid design and operation of reactors towards decarbonization
A 2-D Model to predict the inner state of blast furnace and can be used to study innovations such as tuyere injections and shaft injections
A 2-D Model to predict the inner state of blast furnace and can be used to study innovations such as tuyere injections and shaft injections.
A simulator to help in predicting the temperature and gas composition profile along the length and height of the straight grate process.
Effort is on developing models for other important steel making processes such as BOF, ladle operations, continuous casting etc.
I aimed to develop a 2-D model to simulate complex physico-chemical phenomena in blast furnaces, which involve solid, liquid, and gas phases. At IIT Bombay, with Prof. N. B. Ballal and over 30 master students, we created a comprehensive 2-D model
Initially, the program was far from industrial use, but two years ago, Tata Steel approached me to develop a robust model using OpenFOAM. Collaborating with Tridiagonal Solutions Pvt. Ltd., we combined our research, Tata Steel's experience, and OpenFOAM's flexibility to create BlaSIM
My work in blast furnace modeling led me to northern Sweden, where I served as the LKAB chair professor focusing on the induration of magnetite pellets. I realized that existing models only predicted overall reactor efficiency, not pellet quality. To address this, I designed experiments to understand each phenomenon in isolation and quantify the physics involved.
Using heating microscope experiments, I developed the Single Pellet Induration Model (SPIM) for LKAB. The experiments focused on understanding sintering of magnetite and hematite, oxidation of magnetite, and associated heat transfer.
Efforts are ongoing to develop models for key steelmaking processes such as BOF, ladle operations, and continuous casting. These models integrate experimental knowledge for quantitative predictions.At IIT Bombay, I was involved in the technology transfer of the Electro-Slag Refining Process, leading to the installation of an ESR plant
In collaboration with Prof. S. Seetharaman of KTH, Sweden, we explored using CO2 instead of O2 in Fe-C-Cr melt to reduce Cr oxidation losses, resulting in a model for oxidation phenomena. We are planning further research with Tata Steel, IIT Bombay, and the University of Science & Technology, Beijing
As a dedicated teacher and researcher, my primary goal is to create a dynamic learning environment that nurtures the development of skilled professionals through classroom instruction, laboratory experiments, industrial training, and research projects. I have always believed that teaching and research are two sides of the same coin in academia, a belief that has guided my career. Inspired by passionate teachers throughout my education, I strive to instill the same dedication in my students. My journey in academics began at the Indian Institute of Technology in 2000, where I benefited from mentors like Prof. N. B. Ballal, whose guidance helped me grow as an academician. I prioritize quantitative aspects in metallurgical engineering, using innovative teaching methods to enhance student learning, and have received multiple teaching excellence awards based on student feedback
In research, I have pursued significant projects such as the development of a comprehensive two-dimensional blast furnace simulator (BlaSIM) with the support of numerous master students and collaborators, and the creation of the Single Pellet Induration Model (SPIM) during my tenure as the LKAB Chair Professor in Sweden. My efforts extend to other crucial steel-making processes, including BOF, ladle operations, and continuous casting, integrating experimental knowledge for quantitative predictions. Additionally, I have been instrumental in establishing the Centre of Excellence in Steel Technology (CoEST) at IIT Bombay, fostering industry collaborations and creating a vibrant steel technology program. These efforts have culminated in numerous national and international publications, reflecting the scientific contributions and collaborative enthusiasm of my research endeavors.I prioritize quantitative aspects in metallurgical engineering and utilize innovative teaching methods to enhance learning. My commitment has earned multiple teaching excellence awards. I have played a significant role in developing the M.Tech program in Steel Technology, aiming to elevate the quality of professionals in the steel industry. Through various courses and workshops, I focus on improving the curriculum's analytical and quantitative content, ensuring it meets the evolving demands of the industry
We thank all the funding agencies and collaborators for their support.
