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Scientific activities of Department in the 20th century

Since the foundation of the department, its pedagogical and scientific activities have been tied to general chemical technology – one of the most fundamental applied sciences. The first head of the department, Professor Maksym Isidorovych Nekrych, is the author of a textbook on the course of general chemical technology, and in total during his life he published about 130 scientific papers. Research carried out under his leadership has been implemented in industry – in particular, the process of mechanical pouring of caustic, obtaining iron sulfide from pyrite, etc.

The next head of the department is Doctor of Technical Sciences, Professor Hryhoriy Kostyantynovich Goncharenko, a well-known scientist in the field of diffusion processes and technology of natural gas use. During his educational and scientific activities, he published more than 150 scientific papers. In the early 1960s, the head of the department and his graduate student, and later – Professor of the department A. P. Gotlinska, created a new theory of the mass transfer mechanism in the “liquid–liquid” system (the theory of “resolvation”), which received wide resonance in our country and abroad.

For almost 30 years since the foundation of the department, the main areas of scientific work have been mathematical modeling of chemical and technological processes, the development of intensive methods and equipment for mass transfer processes.

Since the beginning of the 1950s, in connection with the development of nuclear energy, new extraction processes created by the scientists of the department began to be introduced into the industry (extraction is one of the methods for separating uranium and plutonium isotopes). The assessment of the significant contribution of the department to science in this field was reflected in its assignment of the status of the “Kharkiv School of Extraction”. Extraction work was carried out in “liquid-liquid” systems, as well as in the “liquid-solid” system (mostly of plant origin).

In the mid-1960s, on the initiative of Associate Professor, later Doctor of Technical Sciences, Professor Viktor Ivanovych Kovalenko, the department began to develop a new scientific direction – mathematical and computer modeling of chemical and technological processes. For the first time in Ukraine, a laboratory for modeling chemical and technological processes on analog computers was created at the department of chemistry and the discipline “Modeling of chemical and technological processes” was developed.

The result of scientific research by Professor G. K. Goncharenko, his students and followers: Professor A. P. Gotlinska, in the future – university professors I. S. Chernyshov and V. O. Leshchenko, associate professors V. Ya. Shuteyev, V. P. Mykhailichenko and V. M. Solovey, senior researchers S. V. Volyuvach, G. A. Obodovskyy and others in the field of liquid extraction were the following developments:

  • wastewater treatment technology of industrial enterprises (Kharkiv Malyshev Transport Engineering Plant, Rubizhansky Chemical Plant, Shebekinsky Chemical Plant, oil refineries of Western Ukraine, Bashkiria, Eastern Siberia, etc.);
  • intensification of extraction equipment (new types of extractors have been created – screw, tubular, centrifugal, etc.);
  • improvement of static mixers for homogenization of liquid media, which ensure optimal energy use, high efficiency and productivity with minimal dimensions and simple design;
  • use of static mixers in industrial wastewater treatment schemes from petroleum products at a number of machine-building plants;
  • separation of low molecular weight acids by extraction method (Shebekinsky and Volgodonsky chemical plants);
  • intensive methods of extraction processes (Belgorod Vitamin Plant, Kharkiv Pharmaceutical Association “Health”, Lviv Pharmaceutical Plant, food and pharmaceutical plants in Ukraine, Russia, Georgia).

To carry out research work, the department’s employees V. F. Volovod, O. Yu. Averbakh, V. P. Zadorozhny and O. M. Nikitin created a laser Doppler velocity meter, which was a unique device for the mid-1970s. With the help of this device, fundamental studies of the hydrodynamic characteristics of flows in static mixers and plate heat exchangers were carried out.

In the field of extraction in the “liquid-solid” system, Professor G. K. Goncharenko and his followers – senior lecturers, later university professors E. I. Orlova and I. O. Nechyporenko, were the first to carry out a qualitative and mathematical description of the kinetics of extraction, developed a modeling method that allowed obtaining reliable data on the speed and completeness of extraction. Scientists of the department were the first to propose the use of ultrasound to intensify the extraction of medicinal substances from plant raw materials, developed designs of ultrasonic extractors, established the parameters of the most rational process mode and obtained its mathematical description. They also created an original method of extraction from finely ground material and an apparatus for processing such raw materials.

The purpose of solid-phase extraction research was to study the features of extracting biologically active substances from medicinal plant raw materials and to improve extraction equipment. According to the project developed by the department staff under the leadership of I. O. Nechyporenko, for the first time in the USSR, an extraction section for processing finely ground plantain leaves was created at the Zdorovya plant.

Practical interest was aroused by the developed methods of intensification of the extraction process in periodic conditions. Thus, for the first time, based on the studied effect of the influence of transverse unevenness of the extractant movement and its dependence on the direction and speed of fluid movement through the layer of raw materials in the apparatus, a method for calculating an industrial apparatus taking into account transverse unevenness was created. Scientific developments in this area have been implemented at Tbilisi, Tashkent, Kharkov and other chemical and pharmaceutical plants, as well as at food enterprises in Ukraine and Russia.

Research on liquid extraction, which was started by Professor G. K. Goncharenko, was continued by his student – Associate Professor I. S. Chernyshov with his colleagues (junior researchers S. V. Prudius and T. I. Pomazanovska). Their scientific interests were related to the study of statics of complex extraction systems of the pharmaceutical industry, fatty acid industry and other industries. Along with the study of process statics, a fundamentally new hardware design of extraction processes was developed, which took into account the specific properties of pharmaceutical systems, as well as thermostable systems that require maximum shortening of the contact time of the phases.

When studying the statics of pharmaceutical extraction systems, the method of laboratory process simulation was successfully used for the first time in the USSR, which allowed significantly reducing the time for introducing new drugs into production, and at the design stage, choosing the optimal process scheme and calculating all its necessary parameters. The results of the developments were implemented at the Kharkiv pharmaceutical enterprises “Zdorovya” and “Chervona Zirka”, Lviv and Darnytsia chemical and pharmaceutical plants, Simferopol essential oil plant, and Shebekinsky chemical plant.

In parallel, the department carried out scientific research on other topics important for industry. Together with UkrNDIHimMash, work was carried out on the study of heat and mass transfer processes and devices (Associate Professor A. P. Gotlinska):

  • research into heat and mass transfer in devices made of polymer materials, development and research of domestic heat exchangers made of fluoroplastic;
  • deep concentration of solutions in rotary thin-film apparatuses for the processes of drying organic synthesis products (Volga Organic Synthesis Plant), evaporation of titanium tetrachlorides from metal chloride pulp and thermal desalination of ferrous metallurgy wastewater (Berezniki Titanium-Magnesium Combine, etc.);
  • development and research of an optical device of the “Endoscope” type, which allows for visual monitoring of processes occurring in rotary devices and determining the size of individual thermal zones;
  • development and research of highly efficient contact elements of mass exchange columns – based on the results of the work, a qualitatively new classification of contact elements was proposed based on the distribution of gas (steam) and liquid flows.

Based on these and previous developments in the indicated scientific direction, the monograph “Contact Elements of Mass-Exchanging Columns” was published, for which the USSR Higher Attestation Commission awarded the title of professor to the head of the research, Associate Professor A. P. Gotlinskaya.

From 1940 to 1970, Associate Professor Kateryna Gavrylivna Sedashova was engaged in research relevant to the chemical industry – the study of the process of catalytic oxidation of ammonia with oxygen from the air on platinum group catalysts, issues of the duration of operation of such catalysts and their regeneration.

The followers of the ideas of Professor M. I. Nekrych in the field of processing sulfide salts, which were materialized in the corresponding technological processes implemented at industrial enterprises of the USSR, were Associate Professor V. G. Novikov and Senior Researcher O. K. Belyaev.

At different times, such prominent scientists of the university worked at the department as the head of the automation department, Doctor of Technical Sciences, Professor V. T. Efimov, the head of the plastics technology department, Doctor of Technical Sciences, Professor I. M. Nosalevych, Doctor of Technical Sciences, Professor A. N. Tseytlin, Professor I. I. Lytvynenko, and others.

Since 1972, the department began to develop a scientific and practical direction in the use of machines in food technology. The group of scientists working on this topic included senior researcher, later associate professor, professor, doctor of technical sciences Yu. P. Kudrin, senior researchers Yu. A. Tolchinsky and V. K. Lozhechnyk, researcher V. M. Gerashchenko, engineers O. I. Rustynova, L. O. Kupets, Yu. I. Chernysh, G. D. Reznikov.

They investigated the physical and mathematical modeling of presses of hydrodynamic, thermal and mechanical nature in the channels of screw machines and put forward the idea that in many food technologies it is effective to use double-worm extruders instead of single-worm ones. On this basis, calculation and design work was carried out to create high-power double-worm extruders. The ultimate goal of the work was to re-equip the oil materials processing industry with modern machines.

The solutions proposed by Yu. P. Kudrin, Yu. A. Tolchinsky and V. M. Gerashchenko in a systematic form later, at the turn of the century, went beyond the borders of the former Soviet Union and were applied in Romania, Bulgaria, Vietnam, China and a number of African countries. The total output of twin-worm extruders with a working chamber diameter of 75, 85, 100 and 150 mm is currently about 5-10 thousand units with a cost of about 100 million dollars.

The researchers replaced the existing equipment for producing toilet soap with extruders of various types; for the first time in a single model, the material flow was associated with saponification reactions. They also performed work on the kinetics of solid-state chemical reactions in polycrystalline substances under pulsed critical and supercritical loads (in the region of superplastic flow with melting). As a result, pulsed contact conveyor devices based on the Bridgman anvil were calculated for microtonnage implementation of mechanochemical reactions in powders of polycrystalline materials.

In the late 1970s, the department was equipped with digital computers “Mir-2” and “Nairy”. To conduct educational work on the CCM, a specialized computer center (SOC) was organized in the radio building for students of all chemical specialties of the institute. The first engineers who served the SOC were V. P. Lazareva, T. O. Morgun, A. M. Bolotenko, O. V. Brazhko, L. V. Solovey, V. M. Kostin. The teachers who conducted classes using the CCM were associate professors, and later professors Z. M. Tsaryova, A. V. Satarin and E. I. Orlova. They developed the course “Use of computers in chemistry and chemical technology”.

In the late 1970s, the department’s staff numbered about 150 employees, of which about 80 were research staff working in five scientific areas. The volume of scientific research conducted at the department varied from 100 to 200 thousand rubles in different years, and the economic effects of the implementation of scientific developments carried out by the department’s employees reached half a million rubles per year.

Heading the Department of Chemical and Mass Exchange, PA, Professor L. L. Tovazhnyansky laid the foundation for a new scientific direction for the department in the study and intensification of heat and mass exchange processes in complex homo- and heterophase systems. Soon, in the course of research conducted in this direction, methods for calculating heat exchange devices for carrying out chemical and thermal processes in various industries were developed. The employees of the department, who defended their candidate dissertations under the guidance of the new head of the department (now University Professor P. O. Kapustenko, Associate Professor O. G. Nagorna, Senior Researcher M. S. Chus, Senior Researcher O. O. Perevertaylenko), performed a set of theoretical studies to create methods for calculating the thermal and hydromechanical characteristics of plate heat exchange devices for various industries.

Experimental and pilot studies of the created designs of heat exchange equipment were carried out on the basis of UkrNDIHimMash by highly qualified employees of the department: senior researchers M. S. Kedrov and I. B. Derevyanchenko, leading engineers I. B. Yermolaeva, O. A. Fokin, I. V. Moiseeva, etc. Theoretical studies, which were confirmed by experiments, became the basis for the creation of fundamentally new designs of heat transfer surfaces and plate heat exchangers for various processes of chemical technology. These processes include heating, cooling and condensation of vacuum vapors from steam-gas mixtures. Some of the developed designs of plate heat exchangers currently have no analogues – for example, plate heat exchangers of a special design for ammonia and methanol synthesis columns. Original designs of semi-collapsible plate heat exchangers, designs of plate packages and channels with variable geometry were also proposed. New principles for calculating plate heat exchange equipment were developed, which formed the basis for the publication of relevant technical guidance materials (KTM) – regulatory documents of the national level in the USSR.

Professors L. L. Tovazhnyansky and Z. M. Tsaryova, with the participation of senior lecturer and then associate professor E. D. Ponomarenko, first performed systematic studies of mathematical models of the functioning of modernized ammonia synthesis columns with plate heat exchangers as autothermal reactors. Computational experiments were performed to analyze the equilibrium state of the ammonia synthesis reaction under industrial conditions, and to study the kinetics of the ammonia synthesis process based on the analysis of the Tyomkin-Pyzhov equation. Mathematical, algorithmic and software for computer modeling of an axial-type ammonia synthesis reactor were also developed, as well as studies of thermal stability and optimality of the functioning of an axial-type reactor with a certain influence of external regulating and disturbing actions, calculation of the bypass displacement zone, and design calculation of a plate heat exchanger. An analysis of the thermal stability of the autothermal ammonia synthesis reactor system with an axial-type reactor, identification of the degree of catalyst activity using the temperature diagnostics method, computer modeling of the axial-radial reactor, and analysis of the thermal stability and optimality of the functioning of the autothermal ammonia synthesis system with an axial-radial reactor were carried out.

As a result of the work carried out, unique designs of special plate heat exchangers for ammonia synthesis columns were created and introduced into production, which have no analogues in the world. The results of the work carried out were reflected in four textbooks, two training manuals and numerous articles. As part of the deepening of the program for mastering the course “General Chemical Technology” in 1986, the “Higher School” publishing house in Kyiv published a textbook by professors of the department Z. M. Tsareva and E. I. Orlova “Theoretical Foundations of Chemical Technology”.

The scientific team, headed by Professor L. L. Tovazhnyansky, (P. O. Kapustenko, O. Yu. Perevertaylenko, etc.) together with UkrNDIHimMash, VNDIHimMash and the State Institute of Nitrogen Industry developed plate heat exchangers for synthesis blocks and monoethanolamine gas purification blocks of ammonia synthesis units of large unit capacity, as well as for the production of strong nitric acid. Together with the NDIOHim Institute, the department carried out work on the implementation of energy-saving measures through the use of plate devices in technological schemes of soda industry enterprises.

The introduction of plate heat exchangers and their systems, developed at the department under the leadership of Professor L. L. Tovazhnyansky, was carried out at more than three dozen industrial enterprises of the USSR and CIS countries:

  • Severodonetsk VO “Azot”;
  • Mariupol Metallurgical Plant named after Ilyich;
  • “Salavatnaftoorgsintez” JSC;
  • VO “Angarsknaftoorgsintez”;
  • Bereznikovo VO “Azot”;
  • VO “Kuibyshevazot”;
  • VO “Togliattiazot”;
  • Sterlitamak Industrial Complex “Soda”;
  • Chirchytsky State Enterprise “Electrokhimprom”;
  • Grodno VO “Azot”;
  • Vakhsh Voivodeship “Azot”;
  • Kharkiv Chemical Pharmaceutical Association “Health”;
  • Voskresensky Chemical Plant, etc.

The fruitfulness of the scientific ideas of Professor L. L. Tovazhnyansky was reflected in the theoretical studies of hydrodynamics and heat transfer in channels with periodic multiple flow reversals carried out by P. O. Kapustenko and O. G. Nagornaya. Their research has become fundamental, and is now referred to by leading scientists in the world.

In the 1980s and 1990s, the laboratory of optical diagnostics of flows established at the Department of Chemical Engineering and Physics, PA, studied local turbulent characteristics of flows in models of channels of complex geometric shape using the method of laser Doppler anemometry. The research was carried out by V. P. Zadorozhny, O. N. Nikitin, O. Yu. Perevertaylenko, and Y. V. Kireev. A similar technique was used in studies of hydrodynamics in models of static mixers, which were carried out by O. Yu. Averbakh and V. M. Solovey.

Approximately in this same period of time, senior researcher, candidate of technical sciences L. M. Ulyev, later – leading researcher, professor of the department, doctor of technical sciences, carried out fundamental theoretical research on the flow of high-viscosity liquids in conical channels, which were later recognized by world science. Thanks to the conducted research, methods for solving problems of the flow of viscous and high-viscosity liquids in coaxial channels were created, which allow studying the initial hydrodynamic section, which is important for identifying corrections to the pressure calculation. As a result of the research, simple analytical dependences were obtained for calculating the velocity and pressure fields in the flow of viscous liquids in coaxial conical channels, which are used in equipment calculations. The obtained analytical solutions of hydrodynamic problems became the basis for studying convective heat transfer in forced laminar flow of viscous liquids in confluent and diffuser coaxial conical channels.

Even before the 1990s, the Department of Chemical Engineering and Engineering Physics also developed research on the creation of high-temperature electrical insulating and erosion-resistant coatings for gas turbine engine (GTE) elements. These issues were addressed by Associate Professor Valery Yevgenovych Ved, later Doctor of Technical Sciences, Professor; research fellows N. I. Guseva, O. G. Verba, O. M. Antoshyna, O. Ya. Kazakov, engineers O. V. Yurchenko, L. D. Selivanova, V. V. Favorska, laboratory assistants V. B. Lavryshko, A. E. Kaznacheev, A. M. Grebinnyk. The conducted research allowed to discover a new class of high-temperature materials – viscoplastic ceramics, on the basis of which it became possible to create ceramic materials and coatings of higher refractoriness with abnormally high heat resistance. The tools for discovering a class of such materials and developing new ceramics with unique properties were the creation of original devices and equipment for studying the properties of materials at high temperatures.

Theoretical work in the field of high-temperature materials science, carried out by Associate Professor V. E. Ved and his colleagues, allowed to perform, by order of almost all enterprises of the USSR Ministry of Aviation Industry, sensor substrates for determining the thermal and vibration-stressed state of compressor, working and nozzle blades of turbines, fuel pipelines, valve cavities of combustion chambers and nozzles of modern aviation gas turbine engines of various types and designs.

The developed materials allowed to increase the measurement temperatures and stress levels in turbine elements from 600 to 1200 °C on heat-resistant alloys and up to 1500 °C on ceramic gas flow temperature sensors and ceramic turbine blades, maximum temperature meters based on irradiated diamonds. The works were implemented at the enterprises of the USSR Ministry of Aviation with an economic effect of more than 2 million rubles. The developed high-temperature electrical insulating materials with high adhesive properties were also used in radiant flux receivers installed on the outer surface of the Iskra-2 artificial satellites.

Within the framework of this scientific direction, by order of enterprises of the Ministry of General Mechanical Engineering of the USSR, electrically insulating corrosion-resistant coatings for the working bodies of spacecraft orientation engines with an operating temperature of up to 1500 ° C were developed. Coating materials and the technology of their application were introduced for serial production of engines.

The work on determining changes in the composition of oxygen-containing groups during the operation of polyolefins and the selection of methods for directed modification of the composition of secondary polymers, carried out at the department under the leadership of Professor, Doctor of Technical Sciences I. M. Nosalevych, his graduate student, and later professor of the university S. I. Bukhkalo, and his colleagues, allowed to reveal the possibility of recycling a significant part of polymer waste, which traditionally makes up part of landfills. A rotary sintering machine was developed for the processing of polymer waste in conjunction with the KhSKTB “Mashpriborplastik”. These studies helped to partially solve the country’s environmental problems, and the introduction of the results of the work into industry contributed to an increase in the range of products made of plastic masses for technical purposes.

The implementation of scientific research work and the functioning of two educational laboratories and a computer center would not have been possible without the participation in the material support of the department by the head of the laboratory M. D. Korobova, the training master L. Z. Livson, the teaching and support staff – engineer V. O. Patsenko, laboratory assistants G. M. Sychova and N. M. Golubova. The computer center was equipped with modern computers for its time – first a DVK, and then a display class, which was connected to a large institute machine 1061, and even later – the Iskra 1030 computer, HT and AT.

Laboratory work was created and designed by assistant, then associate professor T. G. Babak, and engineer, now associate professor E. D. Ponomarenko. Methodological materials for students’ work at the SOC (a specialized computing center created for students of chemical profiles of the institute) were developed and designed by senior engineer, now senior lecturer L. V. Solovey, engineers S. Yu. Sokolov and I. P. Tokarev, as well as other employees of the department.

In order to introduce into the country’s industry and municipal economy the results of scientific research in the field of plate heat exchangers and energy-efficient heat exchange systems, which were developed at the Department of Chemical Engineering, PA under the leadership of Professor L. L. Tovazhnyansky, in 1991 the Joint-Stock Company “Spivdruzhnist-T” was established on the basis of the Department, with Professor P. O. Kapustenko as its director. In 1994, this company signed a cooperation agreement with Alfa Laval – the world’s largest manufacturer of plate heat exchangers – and became the official distributor of Alfa Laval products in Ukraine, a number of regions of the European part of Russia, Belarus, and Moldova. “Spivdruzhnist-T” still provides comprehensive service for heat exchange equipment in these territories.

On the initiative of Professor L. L. Tovazhnyansky, JSC “Spivdruzhnist-T” organized and mastered the production of plate heat exchangers and modular heat devices, which are used as individual heat points (ITP). Plate heat exchangers are also proposed to be used in the reconstruction of central heat points of heat distribution stations and boiler houses with thermal capacity from 20 kW to 10 MW. Plate heat exchangers of various designs are the main elements of heat devices, which are equipped with pumping equipment, automation and other control means produced by leading European manufacturers. The advantage of modular ITP is their compactness and the ability to regulate the flow of the coolant with their help. This allows you to save up to 15-20% of heat with a payback period that does not exceed two years. Modular ITPs give the greatest effect in the reconstruction of open heat supply schemes.

In the 1990s, a group of researchers at the department (N. I. Guseva, O. G. Verba, etc.) under the leadership of Professor V. E. Ved conducted research on the creation of a technology for applying high-temperature heat-protective erosion-resistant coatings to the internal surfaces of high-purity parts of complex configurations – elements of internal combustion engine exhaust tracts. The created technology for applying and forming heat-protective coatings to the internal surfaces of elements of internal combustion engine exhaust channels directly in the process of casting parts has no analogues. Heat-protective coatings allow reducing fuel consumption of vehicles, increasing the efficiency of engines, and reducing their material consumption.

Under the guidance of Professor L. L. Tovazhnyansky, a postgraduate student, and later a Doctor of Technical Sciences, Professor, Head of the Department of the National Pharmaceutical Academy, Oleksandr Ivanovych Zaitsev, conducted research to determine the optimal parameters of the functioning of column equipment.

In 1992, at the initiative of the head of the Department of General Chemical Engineering, PA Professor L. L. Tovazhnyansky, Professor of the Department P. O. Kapustenko and Professor Jiri Klemes from the Institute of Science and Technology of the University of Manchester, a seminar on promising energy saving methods was held within the framework of international EU projects. A school on modern methods of process integration worked within the framework of this seminar. For the first time in Ukraine and the CIS countries, lectures on pinch analysis and pinch methods of designing chemical and technological systems were given. This was the beginning of the development of a new scientific direction in Ukraine – the method of integration of technological processes.

In 1995, on the basis of the Department of ZHT, PA and the Department of Process Integration of the Institute of Science and Technology of the University of Manchester, with the support of the British Council and the KNOW-HOW Foundation (Great Britain), together with JSC “Spivdruzhnist-T”, the Center for Energy-Saving Integrated Technologies was created, headed by Professor L. L. Tovazhnyansky. This time determines the moment of the foundation of a scientific school of research and training in Ukraine of specialists in the field of theoretical foundations of process integration for the purpose of energy-efficient reconstruction of industrial enterprises or their rational design.

In 1997, a textbook by professors of the department Z. M. Tsareva, L. L. Tovazhnyansky and E. I. Orlova, “Fundamentals of the Theory of Chemical Reactors. Computer Course,” with a volume of 624 pages, was published in Moscow. The textbook was translated into Ukrainian and republished in Kharkiv in 2002.

Fundamental scientific work carried out by the staff of the Department of Chemical Technology, PA became the basis for solving a global industrially important problem in Ukraine – “Development of theoretical foundations of soda ash production technology and equipment and implementation of the concept of building a Crimean soda plant based on complex processing of raw materials from Syvash”. For this work, Professor L. L. Tovazhnyansky and co-authors were awarded the title of Laureate of the State Prize in 1999.