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Testimonials

"Subodh Das has wealth of experience, particularly in the field of Aluminum, has worked on various assignments in the field of aluminum, sustainability, and environment."

Sachin Satpute
Director
Novelis- Korea


"Subodh is extremely knowledgeable about his space and added tremendous value to an aluminum-related transaction we executed at Houlihan Lokey in 2009. Our metals practice would definitely consider hiring Subodh again for diligence support, operations analysis, industry overviews or other expert assistance within the aluminum and light metals industries."

Michael Jenny
Executive Vice President
Houlihan Lokey


"I have known Subodh for several years as he has made several presentations at Metal Bulletin and American Metal Market conferences including events in Chicago, Detroit, and Vienna. He will also be speaking at our International Aluminum Conference in Bahrain. With many years of experience in diverse roles within the global aluminum industry, Subodh is knowledgeable in the several areas of the aluminum process."

Raju Daswani
Managing Director
Metal Bulletin


"SUBODH developed a creative approach to solve the nation's dependence on foreign oil and brought together a group of Fortune 500 CEOs to implement a successful technology advancement effort in the Aluminum production industry. SUBODH brings a rare combination of charisma and deep technical acumen to the field of energy efficiency and technology development. I would partner with SUBODH any time. He is a dynamo!! When I partnered with SUBODH, I was the Department of Energy official leading the nation's efforts to reduce industrial energy consumption by 25%. SUBODH was the major reason that we achieved our goals in the Aluminum industry."

Buddy Garland
Program Manager
US Department of Energy


"Subodh was a driving force behind the Sloan Center for a Sustainable Aluminum Industry at the University of Kentucky. It was a great pleasure to partner with him on the development of the grant and get the Center off the ground. He has enormous energy and a true passion for his work, is knowledgeable, and exhibited great devotion to his employees. He is a doer and I would gladly work with him again on any project."

Paul Jarley
Dean College of Business
University of Nevada at Las Vegas

Most metal producing processes require large amounts of energy (either directly using carbon sources or electricity produced therefrom) contributing to high cost of production and responsible for large amounts of emissions. Many of the processes used to combust carbonaceous materials producing heat are inefficient. Among all the available fossil and renewal sources of energy used in metal producing processes, energy conservation is the cheapest, most abundant and least polluting source with minimum carbon dioxide emissions.

Phinix, LLC provides energy management services to assess energy usage and devising actionable strategies to lower energy consumption and resultant carbon foot print by optimum process design and practices.

“Conserved energy is the cheapest, cleanest and most sustainable source of energy.”

Dr. Subodh Das
“Kentucky Governor’s Conference on Energy and Environment”
Lexington, USA, October 1, 2009


Services Offered

The primary objective of this service is to reduce energy intensity (energy used per unit of production) and to reduce Green House Gas (GHG) emissions associated with industrial manufacturing plants.

Phinix provides energy assessments and audits to identify current performance and provide actionable recommendations to reduce energy use the recommendations include improvements in operating practices, maintenance, retrofit and use of advanced designs for equipment.

Energy management and implementation services are intended to include for all major energy use systems such as process heating, steam systems, compressed air and pumping systems, cogeneration or combined heating-cooling and power generation, and facilities energy use. Process and economic analysis, development of advanced processes and equipment lead to cost reduction and associated reduction in energy and GHG emissions.


Reports Produced

US Department of Energy Contract... “Improving Energy Efficiency in Aluminum Melting DE-FC07-01ID14023”
- Final Technical Report Improving Energy Efficiency in Aluminum Melting DE-FC07-01ID14023 March 2007
- Principal Investigator: Dr. Subodh Das

This project was funded in response to call for proposals under the Aluminum Industry of the Future, Industrial Technologies Program (ITP) of the U.S. Department of Energy (DOE). The objectives of this program are to improve the efficiency of melting in the aluminum industry by;

  • reducing the current energy requirements for melting aluminum by 25%
  • reducing the generation of GHG, and NOx emissions from the melting of aluminum; and
  • evaluating alternate metal melting technologies used in other industries that may have application to further efficiency improvements and emission reductions for the aluminum industry.

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US Department of Energy Contract... "Modeling and Optimization of Direct Chill Casting to Reduce Ingot Cracking"
- Principal Investigator: Dr. Subodh Das

DE-FC36-00ID13897, August 2005

This research project has successfully demonstrated that an increased understanding of the microstructure formation and improved computational tools can be used for improving the DC casting process for aluminum 3004 and 5182 alloys. The results lead to reduced scrap rates and increased energy savings. The project serves as a starting point for even more sophisticated models for the prediction of crack formation.

One of the breakthroughs from this project is having identified that an unfavorable combination of elements in alloys has a strong effect on crack formation. This is especially true when the copper and zinc contents are high in the alloy. Cracking due to the presence of trace elements or due to an unfavorable combination of elements in alloys were not fully recognized in the past and were usually explained as variations due to water quality. One recommendation of the project team is that the industry should pay attention on controlling the composition of the alloys to achieve minimized crack formation.

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US Department of Energy Contract...“Evaluation and Characterization of In-Line Annealed Continuous Cast Aluminum Sheet”
- Principal Investigator: Dr. Subodh Das

DE-FC36-01ID14024, August 2005

A successful project has been completed to understand the feasibility of using in line anneal technique to treat hot roll material as it emerges from the hot rolls. Design, erection and commissioning of a trial facility were successfully carried out at Aleris to produce sufficient amounts of material to evaluate material properties. Based on the successful conclusion of the trials design data has been generated that can be utilized for the construction of an inline anneal based plant either by retroactive fitment of the system or by the construction of a new plant at a Greenfield site.

During the course of the work it was proved that in line anneal can be utilized successfully to produce material comparable to DC cast material at much lower cost and meet the rigorous standards of the automotive industry.

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US Department of Energy Contract...“Reduction of Oxidative Melt Loss Of Aluminum and Its Alloys”
- Principal Investigator: Dr. Subodh Das

DE-FC36-00ID13898, February 2006

This project led to an improved understanding of the mechanisms of dross formation. The microstructural evolution in industrial dross samples was determined. Results suggested that dross that forms in layers with structure and composition determined by the local magnesium concentration alone. This finding is supported by fundamental studies of molten metal surfaces. X-ray photoelectron spectroscopy data revealed that only magnesium segregates to the molten aluminum alloy surface and reacts to form a growing oxide layer. X-ray diffraction techniques that were using to investigate an oxidizing molten aluminum alloy surface confirmed for the first time that magnesium oxide is the initial crystalline phase that forms during metal oxidation. The analytical techniques developed in this project are now available to investigate other molten metal surfaces. Based on the improved understanding of dross initiation, formation and growth, technology was developed to minimize melt loss. The concept is based on covering the molten metal surface with a reusable physical barrier.

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Kentucky Department of Energy Contract "Aluminum Melting Furnace Design Optimization to Improve Energy Efficiency by Integrated Modeling"
- Principle Investigator: Dr. Subodh Das

July 2008; Sponsor: Governor’s Office of Energy Policy, Energy R&D Program

Project team has successfully performed on-site evaluations of commercial furnaces for benchmark and modeling establishment and validation. The furnace modeling tools for furnace design and operation parameter optimization have been developed. The “what if” scenarios studies of furnace re-design for aluminum industrial partners have been carried out for better energy efficiency. The three technical reports have been submitted and discussed with aluminum industrial partners. One project technical review meeting was hold at Lexington, KY. Several aluminum industrial partner specific technical reports were submitted and discussed. Project team will continue to refine the modeling techniques including melting model based on ProCAST, and provide “what if” scenario studies for melting furnace design and operating process optimization to improve energy efficiency.

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Kentucky Department of Energy Contract “Advanced Scalable Clean Aluminum Melting Systems”
- Principle Investigator: Dr. Subodh Das

Funding Agency: KY Office of Energy Policy, December 2007

The results presented in this final report clearly show the strong capabilities of the developed models in the course of this project. Temperature distributions, flow fields and liquid fraction evolutions can be determined for various burner tubes designs and configurations. The results can be used to optimize the design of melting or holding furnaces using immersion heaters. The models can also be used to examine the effectiveness of using immersion heaters for specific functions (e.g. melting, homogenizing molten metal etc.). Numerical simulations are effective and accurate methods of examining potential solutions and can significantly minimize the need for expensive experimental trial and errors.

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Participated in the creation of : "Advanced material for our Energy Future"
- Monogram Produced by Materials Research (MRS), American Society of Metals (ASM), Minerals, Metals and Materials Society ( TMS), American Ceramic Society (ACER) and Associations for Iron and Steel Technology (AIST)

March 2010

Project team has successfully performed on-site evaluations of commercial furnaces for benchmark and modeling establishment and validation. The furnace modeling tools for furnace design and operation parameter optimization have been developed. The “what if” scenarios studies of furnace re-design for aluminum industrial partners have been carried out for better energy efficiency. The three technical reports have been submitted and discussed with aluminum industrial partners. One project technical review meeting was hold at Lexington, KY. Several aluminum industrial partner specific technical reports were submitted and discussed. Project team will continue to refine the modeling techniques including melting model based on ProCAST, and provide “what if” scenario studies for melting furnace design and operating process -optimization to improve energy efficiency.

Read More >


Projects Conducted

  • Dr. Das has conducted and completed many projects for Kentucky Governor’s Office of Energy Policy & Energy R&D Program and US Department of Energy, Industrial Technology Program.
  • Phinix is under current discussions for new research proposals with several potential new and existing clients in the public and private sectors.