Rahul Kumar Soni

@immt.res.in

Principal Scientist
CSIR - Institute of Minerals & Materials Technology

Rahul Kumar Soni


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https://researchid.co/rahulksoni

RESEARCH, TEACHING, or OTHER INTERESTS

Modeling and Simulation, Chemical Engineering, Numerical Analysis
18

Scopus Publications

326

Scholar Citations

10

Scholar h-index

10

Scholar i10-index

Scopus Publications

  • Review on the chemical reduction modelling of hematite iron ore to magnetite in fluidized bed reactor
    Rahul K. Soni, Eswaraiah Chinthapudi, Sunil K. Tripathy, Manaswita Bose, Partha S. Goswami
    Reviews in Chemical Engineering, 2023
    Steel production is considered as one of the major backbones of many economies. Though blast furnace is the primary route of steel production, the industries are willing to alternatives technologies such as the high temperature-controlled conversion of hematite to magnetite. The geological and mineralogical characteristics of the low-grade iron ores possess difficulties in their conventional enrichment. The literature concludes the advantages of high-temperature conversion in terms of easiness in downstream operations caused by decreased hardness and increased magnetic susceptibility of magnetite. The modelling work has been primarily focused on the direct reduction of iron ore to metallic iron. The present compilation discusses the scientific and engineering developments on the reduction-roasting of iron-ore followed by the CFD–DEM modelling and simulation work performed to reduce iron ore to magnetite. It provides a comprehensive review of the experimental and industrial progress done in the area.
  • CFD and DEM numerical modelling of industrial vibrating desliming screen for performance optimization and minimal misplacement
    Rahul K. Soni, Soni Jaiswal, S. Dash, C. Eswaraiah
    Powder Technology, 2023
  • Non-linear steady-state data reconciliation: Theoretical perspective and practical scenarios
    Rahul K. Soni, Swagatika Dash, Eswaraiah Chinthapudi
    Canadian Journal of Chemical Engineering, 2023
    Data reconciliation (DR) is one of the primary error handling methods to reduce measurement errors in industries that may otherwise cause misleading information about the plant. In this article, the mathematical aspects of measurement errors and their treatment by DR are discussed in detail. The flaws in the existing DR methods have been identified and re‐investigated. More importantly, the feasibility and health check‐up of the DR problem have been discussed. The primary objective of the work is to develop a DR code based on the observations made in the present study, which involves DR solutions by both successive linearization (SL) and sequential quadratic programming (SQP) schemes. Benchmarking of the code with standard cases showed its wider suitability in solving DR problems. The algebraic SL method was found suitable for proper data health check‐ups and reliable solutions, whereas SQP was robust. The developed code was tested successfully for a chemical plant as well.
  • An Energy Efficient Advanced Comminution Process to Treat Low-Grade Ferrochrome Slag Using High-Pressure Grinding Rolls
    Talasetti Santosh, Chinthapudi Eswaraiah, Shivakumar Irappa Angadi, Sunil Kumar Tripathy, Rahul Kumar Soni, Danda Srinivas Rao
    Energies, 2023
    The present research aims to analyze the comminution behavior of ferrochrome slag using high-pressure grinding rolls. The laboratory bench scale high-pressure grinding rolls were used to study the three significant variables on the grinding efficiency of ferrochrome slag. The Central Composite Design was used to study the process variables, such as roll gap, applied load, and roller speed. The grinding efficiency was evaluated based on the product size and the energy consumption. The results showed that the increased gap between the rolls and roller speed decreases the product size with increased energy consumption. The results also found that an increase in applied load decreases the product fineness with increased energy consumption. The models were developed for the responses of P80 (size of 80% mass finer) and Ecs (specific energy consumption). Both the responses show high regression coefficients, thus ensuring adequate models with the experimental data. The minimum values of the P80 size and specific energy were determined using quadratic programming. The optimum values of the roll gap applied load and roll speed were found to be 1.43 mm, 16 kN, and 800 Rpm, respectively. The minimum values of P80 and the specific energy consumption were found to be 1264 µm and 0.56 kWh/t, respectively.
  • Size reduction performance evaluation of HPGR/ball mill and HPGR/stirred mill for PGE bearing chromite ore
    T. Santosh, C. Eswaraiah, Rahul K. Soni, Shravan Kumar
    Advanced Powder Technology, 2023
  • Beneficiation Aspects to Improve the Quality of Bauxite Mining Waste PLK Rock
    Satyasish Rout, Santosh Deb Barma, Rahul Kumar Soni, Prasanta Kumar Baskey, C. Eswaraiah, Danda Srinivas Rao
    Lecture Notes in Mechanical Engineering, 2023
  • Modeling and application of stirred mill for the coarse grinding of PGE bearing chromite ore
    T. Santosh, Rahul K. Soni, C. Eswaraiah, Shravan Kumar, D. S. Rao, R. Venugopal
    Separation Science and Technology Philadelphia, 2023
    Platinum group of elements (PGE) mineral is a valuable resource for platinum and other elements. Grinding experiments were conducted in a laboratory-scale stirred mill on a low-grade PGE bearing chromite ore. High-Pressure Grinding Rolls (HPGR) product of −1 mm was used as feed material to the stirred mill experiments. A four-factor (stirrer speed, grinding time, pulp density, and media filling) and a five-level Central Composite Design matrix (CCD) was applied to investigate the stirred mill performance in coarse grinding. The stirred mill grinding efficiency was evaluated based on the particle size distribution and energy consumption. The experimental results showed that the stirrer speed, grinding time, and media filling significantly affect the product size and energy consumption. Pulp density had little influence on the process responses. 3D response surface plots were also discussed in detail to better understand the process variables. A finer size product of 274.7 µm (reduction ratio of 2.63) was achieved at optimal conditions of the stirred mill with an expense of 26.01 kWh/t energy. The results stated that good performance was obtained with the coarser feed size in the stirred mill.
  • Application of artificial neural network method to predict the breakage properties of PGE bearing chromite ore
    T. Santosh, Rahul K. Soni, C. Eswaraiah, Shravan Kumar
    Advanced Powder Technology, 2022
  • Optimization of stirred mill parameters for fine grinding of PGE bearing chromite ore
    Santosh T., Rahul K. Soni, Eswaraiah C., Rao D. S., Venugopal R.
    Particulate Science and Technology, 2021
    The depletion of high-grade ores has forced the utilization of low-grade ores. The small liberation sizes in the low-grade ores require fine grinding which is an energy intensive operation. In the present study, low-grade chromite ore bearing platinum group of elements (PGE) was used as an experimental material. The previous study concluded the liberation size of around 1–50 µm for chromite ore bearing PGE minerals. Therefore, the target product size for grinding was kept below 50 µm. The wet fine grinding experiments were performed in a vertical stirred mill. Four significant operating variables stirrer speed, grinding time, feed size, and solids concentration were investigated for their effect on the performance of stirred mills. The performance of the mill was assessed in terms of achieving small product size at lower energy consumption. The detailed investigations were carried out according to popularly adopted methods of statistical design of experiment. The results revealed that stirrer speed, grinding time, and feed size played crucial role on the performance of stirred mill. Mathematical correlations were developed for predicting product size and energy consumption. The models developed were then optimized using quadratic programing to minimize the combination of product size and energy consumption.
  • DEM numerical studies on the design and efficiency of the continuous operating triboelectric separator
    Rahul K. Soni, R.K. Dwari
    Advanced Powder Technology, 2020
  • Particle Classification Optimization of a Circulating Air Classifier
    C. Eswaraiah, Rahul K. Soni, Sunil Kumar Tripathy, L.O. Filippov
    Mineral Processing and Extractive Metallurgy Review, 2019
  • Data reconciliation for vanadium balance in an alumina refinery
    Proceedings of the 10th European Metallurgical Conference EMC 2019, 2019
  • Understanding size segregation in tumbling mills
    Rahul K. Soni, B. K. Mishra
    Springer Proceedings in Physics, 2017
  • Numerical analysis of mixing of particles in drum mixers using DEM
    Rahul K. Soni, Rahul Mohanty, Swati Mohanty, B.K. Mishra
    Advanced Powder Technology, 2016
  • A novel and direct approach for modeling and simulation of impact grinding
    Rahul K. Soni, Chinthapudi Eswaraiah, B.K. Mishra
    Advanced Powder Technology, 2015
  • Milling and classification of printed circuit boards for material recycling
    Chinthapudi Eswaraiah, Rahul Kumar Soni
    Particulate Science and Technology, 2015
  • Studies on the effect of electrode plate position and feed temperature on the tribo-electrostatic separation of high ash Indian coking coal
    R.K. Dwari, S.K. Mohanta, B. Rout, R.K. Soni, P.S.R. Reddy, B.K. Mishra
    Advanced Powder Technology, 2015
  • Analysis of model parameter dependency on breakage characteristics of single particle comminution
    26th International Mineral Processing Congress Impc 2012 Innovative Processing for Sustainable Growth Conference Proceedings, 2012

RECENT SCHOLAR PUBLICATIONS

  • Review on the chemical reduction modelling of hematite iron ore to magnetite in fluidized bed reactor
    RK Soni, E Chinthapudi, SK Tripathy, M Bose, PS Goswami
    Reviews in Chemical Engineering 39 (8), 1299-1342 , 2023
    2023
    Citations: 9
  • Non‐linear steady‐state data reconciliation: Theoretical perspective and practical scenarios
    RK Soni, S Dash, E Chinthapudi
    The Canadian Journal of Chemical Engineering 101 (6), 3094-3107 , 2023
    2023
    Citations: 1
  • Size reduction performance evaluation of HPGR/ball mill and HPGR/stirred mill for PGE bearing chromite ore
    T Santosh, C Eswaraiah, RK Soni, S Kumar
    Advanced Powder Technology 34 (1), 103907 , 2023
    2023
    Citations: 28
  • Beneficiation Aspects to Improve the Quality of Bauxite Mining Waste PLK Rock
    S Rout, SD Barma, RK Soni, PK Baskey, C Eswaraiah, DS Rao
    Sustainable Chemical, Mineral and Material Processing: Select proceedings of … , 2022
    2022
  • Application of artificial neural network method to predict the breakage properties of PGE bearing chromite ore
    T Santosh, RK Soni, C Eswaraiah, S Kumar
    Advanced Powder Technology 33 (3), 103450 , 2022
    2022
    Citations: 11
  • DEM numerical studies on the design and efficiency of the continuous operating triboelectric separator
    RK Soni, RK Dwari
    Advanced Powder Technology 31 (4), 1624-1632 , 2020
    2020
    Citations: 12
  • Optimization of stirred mill parameters for fine grinding of PGE bearing chromite ore
    T Santosh, RK Soni, C Eswaraiah, DS Rao, R Venugopal
    Part. Sci. Technol 39 (6), 663-675 , 2020
    2020
    Citations: 34
  • Particle classification optimization of a circulating air classifier
    C Eswaraiah, RK Soni, SK Tripathy, LO Filippov
    Mineral Processing and Extractive Metallurgy Review 40 (5), 314-322 , 2019
    2019
    Citations: 17
  • Data Reconciliation for Vanadium Balance in an Alumina Refinery
    S Dash, RK Soni, S Mohanty, A Vihar
    Proceedings of EMC, 5 , 2019
    2019
  • Understanding size segregation in tumbling mills
    RK Soni, BK Mishra
    International Conference on Discrete Element Methods, 1153-1168 , 2016
    2016
    Citations: 13
  • Numerical analysis of mixing of particles in drum mixers using DEM
    RK Soni, R Mohanty, S Mohanty, BK Mishra
    Advanced Powder Technology 27 (2), 531-540 , 2016
    2016
    Citations: 103
  • Preliminary CFD studies of a continuous industrial scale fluidized bed roaster
    S DASH, RK SONI, S MOHANTY, BK Mishra
    a a 1, 2 , 2015
    2015
    Citations: 3
  • Milling and classification of printed circuit boards for material recycling
    C Eswaraiah, RK Soni
    Particulate Science and Technology 33 (6), 659-665 , 2015
    2015
    Citations: 20
  • A novel and direct approach for modeling and simulation of impact grinding
    RK Soni, C Eswaraiah, BK Mishra
    Advanced Powder Technology 26 (3), 1031-1039 , 2015
    2015
    Citations: 12
  • Studies on the effect of electrode plate position and feed temperature on the tribo-electrostatic separation of high ash Indian coking coal
    RK Dwari, SK Mohanta, B Rout, RK Soni, PSR Reddy, BK Mishra
    Advanced Powder Technology 26 (1), 31-41 , 2015
    2015
    Citations: 50
  • Milling and Classification of the Printed Circuit Boards (PCBs) for Material Recycling
    C Eswaraiaha, RK Sonib, R Sakthivela
    Particulate Science and Technology 33 (10.1080), 02726351.2015 , 2013
    2013
    Citations: 2
  • Study of Discrete Element Method (DEM): Methodologies and Applications in Mineral Engineering & Grinding Mill Simulation with MillSoft© 1997
    RK Soni
    Indian School of Mines, Dhanbad India , 2012
    2012
    Citations: 1
  • Studies and Implementation of Discrete Element Method (DEM)
    RK Soni
    Institute of Minerals and Materials Technology , 2011
    2011
    Citations: 1
  • Bed Breakage Energy Distribution Studies for Energy Intensive Grinding Environment
    RK Soni
    Indian School of Mines, Dhanbad, India , 2011
    2011
  • Kishore Vaigyanik Protsahan Yojana (KVPY)(Department of Science and Technology, Government of India) July 09, 2010 Summer Camp Report on Single Particle Breakage Studies with
    RK Soni
    Institute of Minerals and Materials Technology , 2010
    2010

MOST CITED SCHOLAR PUBLICATIONS

  • Numerical analysis of mixing of particles in drum mixers using DEM
    RK Soni, R Mohanty, S Mohanty, BK Mishra
    Advanced Powder Technology 27 (2), 531-540 , 2016
    2016
    Citations: 103
  • Studies on the effect of electrode plate position and feed temperature on the tribo-electrostatic separation of high ash Indian coking coal
    RK Dwari, SK Mohanta, B Rout, RK Soni, PSR Reddy, BK Mishra
    Advanced Powder Technology 26 (1), 31-41 , 2015
    2015
    Citations: 50
  • Optimization of stirred mill parameters for fine grinding of PGE bearing chromite ore
    T Santosh, RK Soni, C Eswaraiah, DS Rao, R Venugopal
    Part. Sci. Technol 39 (6), 663-675 , 2020
    2020
    Citations: 34
  • Size reduction performance evaluation of HPGR/ball mill and HPGR/stirred mill for PGE bearing chromite ore
    T Santosh, C Eswaraiah, RK Soni, S Kumar
    Advanced Powder Technology 34 (1), 103907 , 2023
    2023
    Citations: 28
  • Milling and classification of printed circuit boards for material recycling
    C Eswaraiah, RK Soni
    Particulate Science and Technology 33 (6), 659-665 , 2015
    2015
    Citations: 20
  • Particle classification optimization of a circulating air classifier
    C Eswaraiah, RK Soni, SK Tripathy, LO Filippov
    Mineral Processing and Extractive Metallurgy Review 40 (5), 314-322 , 2019
    2019
    Citations: 17
  • Understanding size segregation in tumbling mills
    RK Soni, BK Mishra
    International Conference on Discrete Element Methods, 1153-1168 , 2016
    2016
    Citations: 13
  • DEM numerical studies on the design and efficiency of the continuous operating triboelectric separator
    RK Soni, RK Dwari
    Advanced Powder Technology 31 (4), 1624-1632 , 2020
    2020
    Citations: 12
  • A novel and direct approach for modeling and simulation of impact grinding
    RK Soni, C Eswaraiah, BK Mishra
    Advanced Powder Technology 26 (3), 1031-1039 , 2015
    2015
    Citations: 12
  • Application of artificial neural network method to predict the breakage properties of PGE bearing chromite ore
    T Santosh, RK Soni, C Eswaraiah, S Kumar
    Advanced Powder Technology 33 (3), 103450 , 2022
    2022
    Citations: 11
  • Review on the chemical reduction modelling of hematite iron ore to magnetite in fluidized bed reactor
    RK Soni, E Chinthapudi, SK Tripathy, M Bose, PS Goswami
    Reviews in Chemical Engineering 39 (8), 1299-1342 , 2023
    2023
    Citations: 9
  • development of a low cost peanut decorticator for use in Developing countries
    A Mishra, R Soni, J Mangla
    Synergy and Technical Development (Synergy2009) Gödöll_, Hungary 30 , 2009
    2009
    Citations: 9
  • Preliminary CFD studies of a continuous industrial scale fluidized bed roaster
    S DASH, RK SONI, S MOHANTY, BK Mishra
    a a 1, 2 , 2015
    2015
    Citations: 3
  • Milling and Classification of the Printed Circuit Boards (PCBs) for Material Recycling
    C Eswaraiaha, RK Sonib, R Sakthivela
    Particulate Science and Technology 33 (10.1080), 02726351.2015 , 2013
    2013
    Citations: 2
  • Non‐linear steady‐state data reconciliation: Theoretical perspective and practical scenarios
    RK Soni, S Dash, E Chinthapudi
    The Canadian Journal of Chemical Engineering 101 (6), 3094-3107 , 2023
    2023
    Citations: 1
  • Study of Discrete Element Method (DEM): Methodologies and Applications in Mineral Engineering & Grinding Mill Simulation with MillSoft© 1997
    RK Soni
    Indian School of Mines, Dhanbad India , 2012
    2012
    Citations: 1
  • Studies and Implementation of Discrete Element Method (DEM)
    RK Soni
    Institute of Minerals and Materials Technology , 2011
    2011
    Citations: 1
  • Beneficiation Aspects to Improve the Quality of Bauxite Mining Waste PLK Rock
    S Rout, SD Barma, RK Soni, PK Baskey, C Eswaraiah, DS Rao
    Sustainable Chemical, Mineral and Material Processing: Select proceedings of … , 2022
    2022
  • Data Reconciliation for Vanadium Balance in an Alumina Refinery
    S Dash, RK Soni, S Mohanty, A Vihar
    Proceedings of EMC, 5 , 2019
    2019
  • Bed Breakage Energy Distribution Studies for Energy Intensive Grinding Environment
    RK Soni
    Indian School of Mines, Dhanbad, India , 2011
    2011