PSRI Consulting

PSRI has over 160 years of experience and over 225 reviewed publications in fluidization and particle technology

Karl Jacob has nearly four decades of particle technology experience across a wide variety of technologies and products.   He is the founder of the Solids Processing Lab at The Dow Chemical Company and was the leader of the group for 29 years until his retirement in 2018.   Karl has been active in teaching both particle technology and, more broadly, chemical engineering for the last 25 years.    Karl has particular expertise in solids flow, pneumatic conveying, drying and process/product design for particulate materials.   Karl is the section editor for the Solids Processing/Particle Technology section in the current (9th) edition of Perry’s Handbook of Chemical Engineering.


On Tuesday, Feburary 2nd 2021, Karl presented a Webinar about himself. Watch the replay. 


  • The Dow Chemical Company, Midland, MI (1982-2018)
    • Fellow for the Solids Processing Lab having worked on all manner of particulate processes and products.
  • University of Michigan, Ann Arbor, MI, (2015-present)
    • Department of Chemical Engineering Core Faculty– teach course in Solids Processing every fall semester; assist student groups in senior process design
  • Kansas State University, Bulk Solids Innovation Center, Salina, KS (2015-present)
    • Karl has taught post-graduate courses to industrial participants in solids flow and pneumatic conveying.
  • American Institute of Chemical Engineers, New York (2018-present)
    • With my wife, we teach the popular “Chemical Engineering for non-Chemical Engineers” 3-4 times per year in various locations across the US.  
    • For 2020, the class is now taught virtually due to Covid-19.
  • University of Akron, Akron, OH (1996-present)
    • Developed (with George Chase) and taught undergraduate/graduate course in solids processing


B.S.  Chemical Engineering, Case Western Reserve University, 1981


  • 2015 – AIChE – Lawrence B. Evans Award in Chemical Engineering Practice
    • Institute level award recognizing contributions to the practice of chemical engineering
  • 2014 – AIChE Particle Technology Forum Award for lifetime achievement in particle technology
  • 2011 - Elected to the grade of Fellow for American Institute of Chemical Engineers


Deng, Z, Fan, Y, Theuerkauf, J, Jacob, K.V., Umbanhower, P.B., Lueptow, R.M., “Modeling segregation of polydisperse granular materials in hopper discharge”, Powder Technology, 374, 389-398, 2020

Litster, J.D., Michaels, J.N. and Jacob, K.V., “Particle technology in the 21st century: Outcomes of the IFPRI sponsored workshop held in Sheffield, UK in April 2017”, Powder Technology, 366, 144-149, 2020

Xiao, H, Fan, Y, Jacob, K.V., Umbanhowar, P.N., Kodam, M, Koch, J.F., Lueptow, R. M., “Modeling segregation of polydisperse granular materials in hopper discharge”, Chem. Eng. Sci., 193, 188-204, 2019

“Solids Processing and Particle Technology, Chapter 21, Perry’s Handbook of Chemical Engineering, 9th Ed, Green and Southard, eds, McGraw Hill, (2018), K.V. Jacob, Overall section editor, authored/coauthored sections on pneumatic conveying and screening

“Segregation of granular materials in bounded heap flow: a review”, Fan, Y., Jacob, K.V., Freireich, B.J., Lueptow, Powder Technology, 312, 67-88, 2017

Dhodapkar, S.V., and Jacob, K.V., Book Chapter on Pneumatic Conveying for “Handbook of Multiphase Flow” 2nd ed., Clayton Crowe, editor, published September 2016

Vasquez, N.A., Fan Y, and Jacob, K.V, “Effect of material elasticity and friction on particle dynamics during dilute pneumatic conveying”, Powder Technology, Sept 2016

Dhodapkar, S.V., Jacob, K.V. and Kodam, M., “Determining Discharge Rates for Particulate Solids”, Chemical Engineering Progress, May 2016

Jacob, K.V., “CHoPS – Twenty Years On – Perspectives on Accomplishments in Bulk Solids Handling and the Challenges that Lie Ahead”, Proceedings of 8th Int. Conf. on Conveying and Handling of Particulate Solids, Tel Aviv, May 2015

Jacob, K.V., Freeman, T., Fan, Y., Brockbank, K.,“A Comprehensive Comparison Of Two Processes For Testing Of Powder Flow Properties”, Proceedings of 8th Int. Conf. on Conveying and Handling of Particulate Solids, Tel Aviv, May 2015

Jacob, K.V., Kayrak-Talay, D., Horton, A., “Thermal Conductivity Measurements for Bulk Solids and Powder Beds”, Proceedings of 8th Int. Conf. on Conveying and Handling of Particulate Solids, Tel Aviv, May 2015

Kodam, M., Jacob, K.V., LeBrell, R., “Understanding Limiting Flow Rates During the Discharge of Bulk Solids”, Proceedings of 8th Int. Conf. on Conveying and Handling of Particulate Solids, Tel Aviv, May 2015

Freireich, B.J., Kodam, M., Jacob, K.V., “Exploring the Interplay between Abrasive Attrition and Separation in Cyclones”, Powder Technology, 273 (2015), 210-219

Freireich B., and Jacob, K.V., 2013, “Exploring the Interplay Between Attrition and Separation” Fluidization XIV, ECI, pp. 977-984

G.E. Klinzing, J.B. Pahk, N. Vasquez, K. Jacob, “Frictional force measurements for multiple plugs in dense phase pneumatic conveying of polymer particles; an industry application” Proceedings of 14th IFPS Meeting, Madrid, Spain, June, 2011, ISBN 978-84-96398-42-9

Jae Bum Pahk, Nestor Vasquez, Karl Jacob, George Klinzing, “Frictional force measurement for multiple plugs in dense phase pneumatic conveying of polymer particles; an industry application.”, Powder Technology

Hall, M., Koblinski, B. Jacob, K.V. “New Hypromellose Excipient for Direct Compression” – appeared in the April 2009 issue of Pharmaceutical Technology and was featured on the inside cover

Vasquez, N.A., Jacob, K.V., Dhodapkar, S.V., “Visual analysis of particle bouncing and its effect on pressure drop in dilute phase pneumatic conveying”, Powder Tech., 179(3),

Vasquez, N.A. Jacob, K.V., “Effect of elbow geometry on pressure drop in upstream straight sections during dilute phase pneumatic conveying”, Proceedings of Relpowflo IV, Tromso, Norway

Theuerkauf, J., Dhodapkar, S.V., Jacob, K.V., “Modeling Granular Flow using Discrete Element Method – From Theory to Practice”, Chemical Engineering, April 2008,

Theuerkauf, J., Dhodapkar, S.V., Manjunath, K., Jacob, K.V., Steinmetz, T., “Applying the Discrete Element Method in Process Engineering”, Chem. Eng. & Tech., 26(2), 157-162

Manjunath, K.S., Dhodapkar, S.V., and Jacob, K.V., “Mixing of Solids in the Process Industries”, chapter in book, John Wiley, 2003

Dhodapkar, S.V., Jacob, K.V., “Troubleshooting Pneumatic Conveying Systems”, Chemical Engineering, March 2002

Jacob, K.V., “Particle Technology Past, Present and Future: The Industrial Perspective”, Proceedings of the 3rd Israeli Conference for Conveying and Handling of Particulate Solids”, The Dead Sea, Israel, pp. 1.1-1.7

Jacob, K.V., Carson, J.W., “Practical Approaches to Achieving Mass Flow – When “Standard” Design Techniques Fail”, Proceedings of Reliable Flow of Particulate Solids III Symposium, Porsgrunn, Norway, 537, (1999)

Carson, J.W., Jacob, K.V.,  “Design Considerations when Silos are used as Processing Vessels”, Proceedings of Reliable Flow of Particulate Solids III Symposium, Porsgrunn, Norway, 553, (1999)

Przybylowicz, E.P., et al, Black and Smokeless Powders: Technologies for Finding Bombs and the Bomb Makers, National Academy Press, Washington, D.C., (1998)

Chase, G.G. and Jacob, K.V., “Chemical Engineers Need a Solid Education”, Chemical Engineering Education, (Spring 1998)

Jacob, K.V. and Dhodapkar, S.V., “Gas-Solid Separations”, chapter in Handbook of Separation Techniques for Chemical Engineers, (3rd Ed.), P. Schweitzer, ed., McGraw-Hill, New York, 1997

Nelson, Jr., R.D., Davies, R., Jacob, K., “Teach ‘Em Particle Technology”, Chem. Eng. Ed., 12, (Winter 1995)

Anderson, R.C. and Jacob, K.V., “Entrainment From an Industrial Rotary Dryer”, Drying ’92, Proc. Int. Drying Symp, (8th Ed.), Elsevier, Amsterdam, 1248, (1992)

Jacob, K.V. and Weimer, A.W., “Normal Bubbling of Fine Carbon Powders in High-Pressure Fluidized Beds”, AIChE J., 34, 1395, (1988)

Jacob, K.V. and Weimer, A.W., “High Pressure Particulate Expansion and Minimum Bubbling of Fine Carbon Powders”, AIChE J., 33, 1698, (1987)

Weimer, A.W. and Jacob, K.V., “Bed to Surface Heat Transfer for Vertical U-Tubes in a High Pressure Slugging Hydrogen Fluidized Bed of Carbon Supported Catalyst Powder”, Powder. Tech., 48, 247 (1986)

Weimer, A.W. and Jacob, K.V., “On Bed Voidage and Apparent Dilute Phase Hold-up in High Pressure - Turbulent Fluidized Beds of Fine Powders”,  in Fluidization V, K. Ostergaard and A. Sorensen, ed., Engineering Foundation, New York, 313, (1986)

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