Malhar's age seems to be 28, I think, which would mean he is 10 years older than Kalyani. It makes the most sense given everything else in the story.
As for the new villain - I agree that he looks like RS's brother or something. I also feel like he is Kethki's father/grandfather. The Deshmukh last name is not a coincidence - she is related to them. The Deshmukh family seems to have a never-ending amount of secrets and whatnot. I would not be surprised if AS and RS screwed over RS's younger brother for money or their own respect or something. And all the villains of THR seem to be related to the Deshmukh family anyway.
Also what you said about one track leading into the other is 100% right. Excluding Keshav, all the tracks have been domino effects of one another.
Yup di even kesav indirectly lead to next track of RS being malhars mom's kathil and that lead to his death rakh bhari maang and jhooti chitti.there also continuation is there
Don't know as of now I feel he is RS brother or something and but can't trust CVS twist ke naam pe use mallu ki baba bi bana sakthe he.
Chances of ketki deshmukh being a coincidence is less because any surname could have done I think it is a well planned thing and not a mistake from creatives.