Distillation column- This is a complex technical device. It is more difficult to make than a regular moonshine still. But it is doable at home. And although distillation columns are freely sold, not everyone has the opportunity to purchase them. In addition, at home, especially in rural areas, there are plenty of scrap materials from which you can make a workable structure and enjoy your own homemade drink. An independent design will cost about 2-3 times less than a purchased mini-distillery.
Components of the structure
The homemade device has the same functional parts as its factory counterpart. The column structure consists of the following elements:
- Frame.
- Dephlegmator (refrigerator).
- Nozzles
- Thermal insulating material.
- Electronic assistants.
The moonshine still as a whole additionally contains:
- Coil.
If you make your own distillation column correctly, it can be installed on any tank with a capacity of 20 liters or more. The optimal volume is in the range from 20 to 50 liters, as the calculation shows. When using a tank of a smaller volume, the column can only be heated to operating temperature and get half of the possible product yield.
Using the optimal tank size allows for easier setup optimal temperature. This parameter during rectification is the main one for the production of a quality product. In addition, preparing to distill 2-3 liters of moonshine will take the same amount of time as 8-10 liters. Why use time inefficiently when you can waste more? In addition, this reduces the cost of the product.
Column operating principle
The mash is poured into a cube, which is heated. As a result, alcohol-containing vapor is released.. The vapor is lighter than the liquid and rises to the top of the column. There is a reflux condenser, which is cooled by running water. As a result, the steam condenses and flows down, but along the way it hits special elements. At the same time, the mash continues to boil, and its vapors flow upward, where they mix with the condensate. This continuous process is called rectification. A home-made moonshine still is no worse: a do-it-yourself distillation column will have the same properties as a factory product, subject to the design parameters.
As a result of rectification, the condensate, which is called reflux, is saturated with vapor. And steam, on the contrary, is saturated with phlegm. As a result of this exchange, the lightest vapor particles, which have a high concentration of alcohol, rise upward. Its boiling point is lower than water. From the top of the column, alcohol vapors are discharged into a reflux condenser for purification and saturation, and then into the refrigerator. The result is pure moonshine.
Features of the still
For alembic suitable container, which will respond to the following queries:
- Consists of stainless steel.
- It has a suitable volume - 15−20 liters.
Beginners use a pressure cooker, but for optimal operation of the column, a larger container is required.
Heating of the cube:
- Electricity.
- Gas.
Many will decide to install the cube on kitchen stove, but the height of the column may interfere. Therefore, it is optimal to place the cube on the floor. Accordingly, it is better to heat the mash with electricity.
It is easier to regulate the power of electric heating. For this purpose, I installed a heating element in the cube, and took the voltage regulator from an old TV. The Chatelier principle works - with greater heating, fusel oils enter the body of the product. They are dangerous. Therefore, you need to monitor the heating, and automation copes with this better.
Note! Having a smooth adjustment of the mash heating power will make life much easier. Otherwise, it will be impossible to achieve stable operation from the device.
Application automatic systems control is not absolutely necessary. To do this, it is better to increase your moonshine brewing experience. Therefore, at first, a simple mash heating power regulator is sufficient.
But with time you can automate the process. In addition, many people are sorely short of time. And the automation system in this case is a good help. The process of brewing moonshine will proceed with minimal human intervention. Ready technical solution, which will prevent tails from getting into the product, can be purchased at a specialty store. The task of such a system is to shut off the selection of rectified product at the moment when the temperature in the column ceases to be optimal.
Construction and assembly of the structure
Question self-made The distillation column is considered halfway. Now you need to take on the main components of the structure.
The rectification system drawer consists of:
- Pipes that have insulation and a nozzle.
- Dephlegmator. Includes product selection unit, cooling jacket and temperature sensor.
- Connections for external communication.
Alcohol is a volatile substance that is highly flammable. At the top of the column there is a hole for communication with the atmosphere. You can't leave it open. You need to insert a tube into it and put a rubber tube on it. You can also use a tourniquet.
The end of the tube should be lowered into a container of water.. The presence of bubbles will indicate whether the alcohol vapor is spreading outside the device. If there is excess pressure, and it occurs due to overheating, this will help avoid an accident.
Column tube
This is the nozzle itself for the column. Here the process of interaction between cold phlegm and hot steam occurs. To increase the contact area of these substances, a filler is used. The most common filler is metal scourers for washing dishes. But any stainless steel wire will do. The packing density is about 250 g per 1 liter of column volume.
Note! When using washcloths as a filler, you need to make sure of their quality - boil a piece of washcloth in a saline solution. If the product is made of a metal other than stainless steel, then signs of corrosion will appear. It is necessary to cut the product before testing - manufacturers are cunning and sometimes only apply a protective layer of stainless steel. The internal structure must be exposed.
Pipe size:
- The minimum diameter is 32 mm.
- The length of the requirement affects the quality of the separations into fractions. The longer, the better the separation.
- The optimal height is 40−60 diameters.
- The minimum height is at least 20 diameters.
The outside of the pipe is wrapped with a thermal insulating layer.
In order for the filler to be securely fixed inside the pipe, a stainless steel mesh should be placed on top and bottom of it. The pipe must have a thread for fastening from below to the distillation cube, and from above - for connection to the dephlegmator.
Ideally, the height should be 1.5 m. This will allow you to obtain pure alcohol. Standard version - 2 drawers, 80 cm each.
I fill the apparatus with washcloths and secure them with a tea strainer. At the same time, the pressure does not jump. Output rate - up to 1 liter per hour. Distillation is not as difficult as it seems.
Dephlegmator
Light fractions condense in the reflux condenser. The device may have different designs. In practice, the simplest is a direct-flow dephlegmator. It is also called a shirt or refrigerator capacitor. There are drawings of a reflux condenser on the Internet, but it is easier to make the option described below.
The design is made of two pipes, which have different diameters and are inserted into one another. A cooling jacket is installed between them.
Components:
- Fittings for inlet and outlet of cooling water.
- At the top there is a tube for communication with the atmosphere.
- At the bottom there is a fitting for selecting the product.
Note! To ensure that the quality of the product does not suffer, use only silicone tubes and gaskets as a tapping fitting and seal.
The material for making the reflux condenser can be an old thermos or ordinary stainless pipes. The inner tube is equal in diameter to the nozzle tube. If you don’t have welding equipment at hand, use a soldering iron.
Note! Experts recommend using copper or titanium for moonshine stills. The thing is that copper absorbs sulfur oxide, and this improves the properties of moonshine. But this material is expensive, and it is difficult to work with it at home without welding.
The product selection unit is a washer that is welded into the inner tube of the reflux condenser. Located below. The selection unit must contain the following holes:
- For the sampling tube.
- For the thermometer when using it.
For experienced users, a thermometer may not be needed. But for beginners it is advisable to install it. The operating range of the column is 45−55 degrees of cooling water. You can measure the temperature at the junction of the reflux condenser and the drawer. Then the indicators should be around 77-81 degrees.
Before the end of the pasture, the temperature usually fluctuates.
For effective cooling, a screw spiral should be used. Then running water will flow around the dephlegmator better.
Choosing a refrigerator
Note! Using a Dimroth refrigerator is not advisable. The design differs in that substances with a low boiling point can bypass the cooling zone. A dim rotary refrigerator is good for those liquids that boil at temperatures above 160 degrees.
An air cooler should not be used. Cooling in this case will be ineffective. This would be the case if a steam tank was attached to the distillation column. But in this type of device it is not needed.
A laboratory glass cooler is an ideal alternative. It can be purchased at any laboratory glassware store. To regulate the rate of product selection, the tube from the reflux condenser to the refrigerator should be equipped with a tap. You can use a faucet clamp.
Connection sequence:
- Bottom of the refrigerator.
- Fridge.
- Top of the refrigerator.
- Top of the reflux condenser.
- Dephlegmator.
- Bottom of the reflux condenser.
- Stock.
Cooling running water will move along this route. It is important that it enters the reflux condenser jacket warm.
Ideal design moonshine still with separation of fusel oils - this is distillation column. If the temperature conditions are observed, you can obtain the purest product. But it will be deprived of its original taste.
But in a regular moonshine still - a distiller - you can get moonshine with a pronounced bouquet. For this purpose, a steam tank is used in the design. But there is a nuance - with a bouquet of aromas, moonshine distillate may contain impurities of fusel oils.
Attention, TODAY only!
More and more people are coming to the understanding that store-bought alcohol is not worth the money they ask for it: the quality is low and the prices are too high. For this reason, more and more “moonshiners” are appearing in our country. They start with primitive moonshine stills, but quite quickly come to the idea of creating a full-fledged distillation column with their own hands. But doing it is not as easy as it seems at first glance.
The distillation column has a complex structure. In order for it to work well in the future, its parameters must be accurately calculated. Only in this case will it be possible to count on creating a truly balanced system for home use.
Before you do distillation column To make a moonshine still with your own hands, you need to carefully calculate the parameters of each of its elements, and then purchase all the necessary components that correspond to the calculations.
Characteristics of the drawer and nozzle
In fact, this is the main element of the distillation column. All other parameters of the column will depend on the pipe parameters.
When creating an alcohol column with your own hands, it is best to use a chromium-nickel steel pipe. This is the so-called food grade stainless steel. Due to the fact that this alloy is completely neutral in chemical terms, it will not add any impurities to the final product. This is very important, because the main task of rectification is to obtain pure product without impurities, and not at all a change in its taste and aromatic properties.
Some experts advise using a copper drawer for distillation. Under no circumstances should this be done. The fact is that copper can change chemical composition alcohol. The maximum where copper can be used is a distiller or a mash column.
The drawer must have a wall thickness of at least 1 and no more than 1.5 mm. Thicker pipe walls do not provide any advantages during distillation, but at the same time make the entire structure much heavier. This is unacceptable for a home distillation system.
The drawer must be calculated together with the nozzle. At home, it is customary to use nozzles whose total contact surface area does not exceed 4 m 2 /liter. Of course, you can use nozzles with a larger contact area, but this will only increase the separation capacity of the column, however, it will reduce the overall productivity.
Spiral-prismatic in size the nozzle should be 12 times smaller than the column diameter.
Experienced moonshiners recommend keeping nozzles with different characteristics to use them depending on the situation. So, to obtain fortified moonshine, it is best to place copper rings up to 10 mm high in the column. In this case, copper will effectively remove sulfur compounds from alcohol.
When selecting a frame, you should remember that even a minimal change in the diameter of the column will seriously affect the performance parameters.
Regarding the pipe height, then it should fit within the parameters of 1 to 1.5 m. The height will be less, then fusel oils will penetrate into the selection. At the same time, as the height of the pipe increases, the transfer time increases, but not the separating capacity of the system. That is, it makes no sense to increase the height of the rectifier.
To increase the selection of high-quality alcohol and prevent the tsar from overflowing with fusel, raw alcohol should be poured into the cube no more than 20 volumes of nozzle. On average, the cube is filled to 2/3 of the volume. This means that with a drawer diameter of 50 mm, you need to use a cube with a volume of 40 to 80 liters. If the pipe diameter is 40 mm, then a cube with a volume of 30 to 50 liters is sufficient.
Heat source calculation
Many people think what if the moonshine still can be heated on gas or regular electric stove, then it can also be used to heat a distillation column. This is far from true. The fact is that rectification is very different from the conventional distillation process. If the process of obtaining a distillate allows for heat surges, then during rectification the heating power must be properly regulated. Therefore, neither a gas, nor an electric, nor an induction cooker will work.
Perfect option: installation of a heating element of the required power inside the distillation device with an output voltage regulator for fine tuning.
As for the power of the heating element, to heat a 50 liter cube you need 4 kW of energy, for 40 liters 3 kW, for 30 liters 2 kW.
The heating element must be installed correctly in the cube so that its heating does not cause the mash and raw alcohol to boil. The higher the heating element is, the less power it requires to cause the contents of the cube to boil. As the depth of immersion increases, the power required to boil increases.
Dephlegmator calculation
The power of the reflux condenser is largely determined by the type of distillation column. If you plan to build a column with liquid extraction, then the power of the dephlegmator must correspond to the rated power of the entire column. Most often, this design uses a Dimroth refrigerator, whose utilization power is 5 watts per 1 cm 2 of area.
When creating a distillation column with a fence installed above the dephlegmator, then the power of the latter should not exceed 2/3 of the power of the column. In this case, you can abandon Dimrot and use a “shirt maker”, whose utilization power does not exceed 2 Watts per cm 2.
Calculation of a once-through refrigerator
If the direct-flow unit will be used as additional cooling, then you should choose the simplest and smallest option. Its power should not exceed 30% on the power of the distillation column.
A straight-through refrigerator looks like a straight tube between the drawer jacket and inner tube. The length of the tube usually does not exceed 30 cm.
If the same direct-flow refrigerator will be used not only for distillation, but also for rectification, then the maximum heating during distillation, rather than the rated power of the column, should be taken into account.
The minimum tube diameter is determined by the minimum speed and the maximum kinematic viscosity of the vapor.
- With a power of 1.5 kW, the minimum diameter is 8 and the maximum is 9 mm.
- With a power of 2 kW, the minimum pipe diameter is 9 and the maximum is 12 mm.
- With a power of 3 kW, the minimum diameter is 10.5 and the maximum is 18 mm.
So we have everything on hand necessary calculations with the drawing, and therefore we can begin assembling the distillation column.
You need to prepare the following items distillation apparatus:
- Frame.
- Dephlegmator.
- Nozzle. It can be dish-shaped or spiral.
- Thermal insulation.
- Thermometers.
The tank for raw alcohol can be used from a moonshine still. You also don't have to make a new coil. It can be taken from the same distiller. A correctly calculated and assembled column can be installed on any moonshine still. The main thing is that the tank volume is more than 20 liters. If the volume is smaller, the distillation column will not work.
How to make a king with your own hands?
It is best to make it from stainless pipe. Ideal option – food grade steel.
Experts advise doing it with several joints. At the very bottom of the drawer, a flange is welded, through which it will be attached to the lid of the distillation tank. The flange connection must be airtight, so a gasket must be used. Preferably silicone. Plastic gaskets change shape when exposed to temperature.
The flange must be welded so that the column stands strictly vertical. A deviation of just half a degree will change the quality of the output product.
Individual parts of the column are better connect with clamps. This way, it will be easier to assemble and disassemble the column.
The two lower parts of the drawer are just pipes. They will have nozzles installed to increase the area of contact between the liquid and the steam. But the upper part is quite complicated. It should contain the following structural elements:
- Flow refrigerator.
- Outlet pipe.
- Connector for installing a thermometer.
- Air valve.
The flow cooler accounts for half of the top of the column The simplest option is to wrap the pipe with a copper coil, but it is not very effective. The ideal option is to place a Dimroth cooler inside the pipe. In this case, the reflux condenser will turn the condensate into steam until it reaches the air valve at the highest point of the distillation column.
The outlet pipe should be installed lower refrigerator by a couple of centimeters.
Nozzle
This is one of the most important parts of the column. It comes in 3 types: plate-shaped, sieve and spiral. The first option is much more effective. Many novice moonshiners make a disc nozzle from parts that are freely sold on the Internet.
A sieve attachment is much easier to make. All you need: a drill, disks, and small-diameter drills, stainless steel partitions. Drilling holes in the partitions different diameters and install it inside the pipe.
You can’t make a spiral nozzle yourself, but you can easily buy it in a specialized store.
Some thematic forums and websites advise using dishwashing mesh to create a spiral attachment, but you shouldn’t do this. the fact is that no one knows for certain what alloys they are made of. This means that no one can predict what kind of compounds will be obtained when the mesh material comes into contact with hot alcohol vapor.
Thermal insulation
When assembling the column you must remember to protect it from heat loss at least to the lower limit of the dephlegmator. As insulation, you can use materials such as polyurethane foam, penoizol, foil insulation, etc.
Actually, all that remains is to put all the parts together and test run a homemade distillation column.
Conclusion
Now the reader knows how to make a column for home rectification. All that remains is to put this knowledge into practice and enjoy the purest product.
Even the simplest distillation column, despite low speed distillation will make it possible to obtain a sufficient amount of alcohol both for consumption in its pure form and for the production of more noble drinks based on it.
Also, do not forget that using a distillation column as a moonshine still to produce moonshine will allow you to obtain 30% more product than from a conventional distiller. In addition, the quality of moonshine will be much better.
To obtain pure moonshine, home cooks usually resort to double distillation. The result is a high-quality product without harmful impurities, with pleasant taste and aroma.
An even better effect is achieved by distillation in a distillation column. It allows you to obtain the most purified strong alcohol (94–96%) or vodka without additional tastes and odors.
At the same time, the device has practically no disadvantages, with the exception of its large dimensions and the need to work hard on its manufacture. Most experienced moonshiners agree that it is better to assemble the distillation column yourself.
Design and principle of operation of a distillation column
Alembic
Tsarga (pipe) with filler
Alcohol selection unit
Dephlegmator
Additional refrigerator
It works as follows
The mash in the distillation tank heats up and begins to evaporate. The vapors follow up the drawer, reach the refrigerator and the selection unit, the tap of which is on initial stage closed.
The condensed vapor (reflux) flows back down the pipe. In this case, heavy fractions accumulate at the bottom, and light fractions at the top. Thanks to the nozzles, the processes of condensation and evaporation occur repeatedly: vapors and liquids continuously interact.
This process of exchange is the process of rectification. The lightest vapors with a high alcohol content are sent to the refrigerator, where final condensation occurs. As a result, pure distillate enters the receiving tank.
Calculation of parameters and selection of materials
Before you begin assembling the column, you should decide on the dimensions and other characteristics of the apparatus.
Tsar height
If previously distillation columns were multi-meter structures, today home distillers use compact options - about 1.5 meters long. The main principle that should be followed when calculating dimensions is the following: the height of the pipe should be equal to approximately 50 of its diameters. Slight deviations in one direction or the other are allowed. However, the length of the drawer cannot be less than 1 meter. Otherwise, some of the fusel oils will be selected, and difficulties will arise with the separation of fractions. Increasing the height of the column over 1.5 meters does not significantly affect the quality of the product, but lengthens the hauling time. In addition, placing such a structure at home will be problematic. Optimal sizes pipes: length – 1.3-1.4 m, diameter – 3–5 cm.
Material and wall thickness
The ideal option for the drawer is food-grade stainless steel: it does not affect the composition of the drinks in any way. Copper will also work. Optimal thickness the walls are within 1–2 mm. More is possible, but it will make the structure heavier and increase costs without bringing much benefit. In addition, it is worth remembering that you will have to make holes in the walls.
Type and parameters of nozzles
As a contact element, the easiest way is to use household stainless steel sponges, which are used to clean dishes. To check the quality of the metal, you can soak the product in a salt solution and leave it in it for a day: good product will not rust. Alternative options are glass balls, stones of certain types, metal shavings. The packing density is 250–270 g of contact element per 1 liter of column volume.
Volume of a cube
The distillation container is filled 2/3, and the amount of alcohol-containing liquid should correspond to 10–20 volumes of the nozzle. For a column with a diameter of 5 cm, it is optimal to use a tank of 40–80 l, for a width of 4 cm – 30–50 l.
Heating source
The use of a gas, electric or induction cooker is not recommended. The first option is dangerous, the others do not allow for uniform heat supply. The best option is electric heating using heating elements, which can be installed into the cube yourself. The power of the elements depends on the volume of the cube: for 50 liters at least 4 kW is required, for 40 liters - at least 3 kW, etc.
View thermal insulation material
He must withstand high temperatures, be chemically inert. Typically, foam rubber 3–5 mm thick, fluoroplastic or silicone (but not rubber!) gaskets are used.
Docking option
If used threaded connections, sealant may be required. It is better to give preference to putting elements on top of each other.
When creating a distillation column, every little detail matters, so all recommendations should be strictly followed. It would be a good idea to watch the assembly video.
The selected type of nozzles is poured into one part, which will be located below, after installing a mesh and a thrust washer to prevent the material from falling out. If metal sponges are used (about 40 pieces are required), first cut them into 5 mm pieces. The springs should be distributed evenly by tapping the pipe on a hard surface. Having filled in the nozzle, cover the pipe with a mesh and secure it with a washer.
The resulting structure is connected to the distillation cube and insulated with heat-insulating material.
The second (upper) part of the pipe is connected to the reflux condenser using a soldering iron. The water housing must have 2 pipes: for water inlet and outlet. You can buy a reflux condenser or make it yourself from a thermos, pressure cooker, coil, copper tube(the first options are preferable). For example, like this: https://youtu.be/D4ZsbbRH6ds
The upper end of the column is closed with a stopper/lid or sealed, leaving a hole for installing an atmospheric tube. To secure it, use a fitting, the end of the tube is lowered into water.
Make a hole for the outlet pipe for the distillate. It should be located a couple of centimeters above the junction with bottom pipes, a plate is installed under it to collect condensate.
By using silicone hose connect a refrigerator to the column. You can buy it or make it yourself. To regulate the process of fluid movement, a clamp from a dropper is attached to the hose.
The cooling elements are connected to each other: top part refrigerator with the bottom of the reflux condenser, the upper part of the reflux condenser with a sewer. Thus, the water will be heated to the dephlegmator.
Additionally, you can install a water flow regulator and a thermometer (it will require an additional hole in the sampling unit).
You can also divide the drawer into 3 parts: this design is considered more variable in application. Detailed Process Column assemblies can be viewed here:
§ 13.2 Distillation columns: their design and operation
As mentioned above, rectification is carried out in special devices - rectification columns, which are the main elements of rectification plants.
Rectification process can be carried out periodically and continuously, regardless of the type and design of distillation columns. Let's consider the process of continuous rectification, which is used to separate liquid mixtures in industry.
Distillation column- vertical cylindrical apparatus with welded (or prefabricated) housing in which mass and heat exchange devices (horizontal plates) are located 2 or nozzle). At the bottom of the column (Fig. 13.3) there is a cube 3, in which the bottom liquid boils. Heating in the cube is carried out due to dead steam located in a coil or in a shell-and-tube heater-boiler. An integral part of the distillation column is the reflux condenser 7, designed to condense the steam leaving the column.
The rectification plate column works as follows. The cube is constantly heated, and the still liquid boils. The steam generated in the cube rises up the column. The initial mixture to be separated is preheated to boiling. It is served on a nutrient plate 5, which divides the column into two parts: lower (exhaustive) 4 and upper (strengthening) 6. The initial mixture from the nutrient plate flows onto the underlying plates, interacting on its way with steam moving from bottom to top. As a result of this interaction, the steam is enriched in the highly volatile component, and the liquid flowing down, depleted in this component, is enriched in the highly volatile one. At the bottom of the column, the process of extracting (exhausting) the highly volatile component from the initial mixture and turning it into steam takes place. Some part of the finished product (rectified product) is supplied to irrigate the upper part of the column.
The liquid entering the top of the column to irrigate and flowing through the column from top to bottom is called reflux. Steam, interacting with reflux on all plates of the upper part of the column, is enriched (strengthened) with a highly volatile component. The steam leaving the column is sent to the reflux condenser 7, in which it is condensed. The resulting distillate is divided into two streams: one as a product is sent for further cooling and to the finished product warehouse, the other is sent back to the column as reflux.
The most important element of a plate distillation column is the plate, since it is on it that the interaction of steam with liquid occurs. In Fig. 13.4 shows a diagram of the device and operation cap plate. She has a bottom 1, hermetically connected to the column body 4, steam pipes 2 and drain pipes 5. Steam pipes are designed to pass vapors rising from the bottom plate. Through the drain pipes, liquid flows from the overlying plate to the underlying one. A cap is mounted on each steam pipe 3, by which vapors are directed into a liquid, bubbled through it, cooled and partially condensed. The bottom of each plate is heated by the vapors from the underlying plate. In addition, when steam partially condenses, heat is released. Due to this heat, the liquid on each plate boils, forming its own vapors, which mix with the vapors coming from the underlying plate. The liquid level on the plate is maintained using drain pipes.
Rice. 13.3. Diagram of the distillation column: / - body; 2 - dishes; 3 - cube; 4, 6 - exhaustive and strengthening parts of the column; 5 -nutritional plate; 7 - reflux condenser
The processes occurring on the plate can be described as follows (see Fig. 13.4). Let vapors of composition A flow onto the plate from the bottom plate, and liquid of composition flows from the top plate through the overflow tube IN. As a result of the interaction of steam A with liquid IN(steam, bubbling through the liquid, will partially evaporate it, and will partially condense) a new vapor of the composition will be formed WITH and new liquid composition D, are in balance. As a result of the operation of the plate, new steam WITH richer in volatile substances compared to the steam coming from the lower plate A, that is, there is steam on the plate WITH enriched with a highly volatile substance. New liquid D, on the contrary, it became poorer in volatile matter compared to the liquid coming from the upper plate IN, that is, on the plate the liquid is depleted in the highly volatile component and enriched in the highly volatile component. In short, the work of the plate comes down to enriching the steam and depleting the liquid of the volatile component.
Rice. 13.4. Diagram of the design and operation of a cap plate: / - bottom of the plate; 2 - steam pipe;
3 - cap; 4 - column body; 5 - drain pipe
Rice. 13.5. Representation of the operation of the distillation plate on the diagram at-x: 1- equilibrium curve;
2 - line of working concentrations
A plate on which a state of equilibrium is achieved between the vapors rising from it and the liquid flowing down is called theoretical. In real conditions, due to the short-term interaction of steam with liquid on the plates, a state of equilibrium is not achieved. The separation of the mixture on a real plate is less intense than on a theoretical one. Therefore, to perform: the work of one theoretical plate, more than one real plate is required.
In Fig. Figure 13.5 shows the operation of a distillation plate using a diagram at-X. The theoretical plate corresponds to a shaded right-angled triangle, the legs of which are the increment in the concentration of the volatile component in the vapor, equal to mustache-y A , and the magnitude of the decrease in the concentration of the volatile component in the liquid is equal to x B - x D . The segments corresponding to the indicated changes in concentrations converge on the equilibrium curve. This assumes that the phases leaving the plate are in a state of equilibrium. However, in reality, the equilibrium state is not achieved, and the segments of concentration changes do not reach the equilibrium curve. That is, the working (real) plate will correspond to a smaller triangle than the one shown
in Fig. 13.5.
The designs of the trays of distillation columns are very diverse. Let's briefly consider the main ones.
Columns with cap plates widely used in industry. The use of caps ensures good contact between steam and liquid, effective mixing on the plate and intensive mass transfer between phases. The shape of the caps can be round, multi-faceted and rectangular, the plates can be single- or multi-cap.
A plate with grooved caps is shown in Fig. 13.6. Steam from the bottom tray passes through the gaps and enters the upper (inverted) gutters, which direct it to the lower gutters filled with liquid. Here, steam bubbles through the liquid, which ensures intense mass transfer. The liquid level on the plate is maintained by an overflow device.
Columns with sieve plates are shown in Fig. 13.7. The plates have a large number of small diameter holes (from 0.8 to 3 mm). The pressure of the steam and the speed of its passage through the holes must be in accordance with the pressure of the liquid on the plate: the steam must overcome the pressure of the liquid and prevent it from leaking through the holes onto the underlying plate. Therefore, sieve trays require appropriate regulation and are very sensitive to changes in the regime. If the vapor pressure decreases, the liquid from the sieve trays goes down. Sieve trays are sensitive to contaminants (precipitates), which can clog the holes, creating conditions for the formation of high pressures. All this limits their use.
Packed Columns(Fig. 13.8) differ in that the role of plates in them is played by the so-called “nozzle”. As a nozzle, special ceramic rings (Raschig rings), balls, short tubes, cubes, saddle-shaped, spiral-shaped, etc. bodies made of various materials (porcelain, glass, metal, plastic, etc.) are used.
Steam enters the lower part of the column from a remote boiler and moves up the column towards the flowing liquid. Distributed over a large surface formed by packed bodies, the steam comes into intense contact with the liquid, exchanging components. The nozzle must have a large surface per unit volume, exhibit low hydraulic resistance, be resistant to the chemical effects of liquid and steam, have high mechanical strength, and have a low cost.
Packed columns have low hydraulic resistance and are easy to use: they can be easily emptied, washed, purged, and cleaned.
Rice. 13.6. Plate with grooved caps: A- general form; b- lengthwise cut; V- diagram of the plate operation
Rice. 13.7. Diagram of the sieve plate structure: / - column body; 2 - plate; 3 - a drain pipe; 4 - hydraulic shutter; 5 - holes
Rice. 13.8. Scheme of a packed distillation column: 1 - frame; 2 - input of the initial mixture; 3 - steam; 4 - irrigation; 5 - lattice; 6 - nozzle; 7-outlet of high-boiling product j-. 8 - remote boiler
For home production strong drinks requires modern equipment made from quality material. In stores, manufacturers offer models that are divided into distillers and rectifiers. Many novice distillers are tormented by the question: what is better for home brewing - a column or a moonshine still.
The principle of operation is not much different, but the final product from the distillation column is better and cleaner, and in terms of strength it has no equal, since it is almost pure alcohol. To find out how these devices differ, what technical parameters they have, individual nuances, and whether there are any disadvantages, you need to read this article.
The entire distillation procedure consists of heat exchange that occurs in the product; during the cooling process, the raw material is separated, and the purified substance appears at the outlet of the device. At different heating temperatures you get different substances:
- t=+56 C - we get acetone;
- t=+65 C - methyl alcohol can be isolated;
- and only at t=+78 C is rectified alcohol obtained;
- if we continue heating to the boiling point of water and higher, for example, up to 100 degrees, then at the output we will get water flavored with fusel oils and all sorts of impurities.
The basis of the entire process occurring in the column is the contact of the liquid and vapor states of various substances, as a result of which various vapors are released, which settle in the reflux condenser, and only those containing alcohol pass on.
Additional heating occurs in the evaporator, but only up to +78 degrees, so all harmful impurities and water condense and remain in the device. On different areas product, individual interaction of vapor and condensate occurs, and fractions of different temperature levels precipitate into condensate and flow to the lower part.
A column is a device that has a certain height, with a container elongated along its entire length, so different temperatures are obtained: only alcohol-containing vapors reach the very top, all other fractions fall into condensate, because the temperature is less than what is needed for them to boil. The taste and strength of the final product differs significantly depending on better side from moonshine passed through a standard distiller.
Modern models of columns are characterized by very high productivity, and the alcohol resulting from rectification does not have a fusel odor or foreign impurities.
What is the difference between a moonshine still and a distillation column?
The most important difference: a standard apparatus for home brewing consists of a distillation cube and a refrigerator coil, where condensation of alcohol-containing vapors occurs. Some models have a dry steamer, where high-quality separation of impurities and aromatization of vapors occurs to produce elite alcohol in the form of brandy or whiskey.
The column is a rather complex device; it is mainly intended for purifying already produced moonshine in order to eliminate all the smallest foreign inclusions and obtain pure alcohol. The design is made from of stainless steel, copper or brass, because very complex high-temperature processes take place inside and the corrosion resistance should be quite high.
Bottom part The column is called the tsarga, and the top one is called the cooler or reflux condenser, because it is there that the final separation of the various phlegms occurs. In its cover there is a tube for communication with environment so that the internal pressure does not exceed the permissible value. We have already discussed all the nuances of the work, so we omit them.
The product is installed on a distillation tank or cube, and all connections must be perfectly sealed. At the very top there is an outlet tube for alcohol vapor; the best option is when it also has an additional refrigerator. The height of the product is decent, some samples are up to 2 m, so this design may not fit indoors: 2 m + tank + stove. The best option is to heat the tank on a special stove for home brewing: it has small dimensions, like a tabletop electric stove.
It is not recommended to distill mash through a column, although today manufacturers have already mastered the production of improved samples that can cope with this application. The verdict is simple: moonshine stills are designed for distilling raw alcohol, and the column can clean it almost completely of odor and harmful impurities.
Remember! A distillation column is used to obtain pure alcohol, and if you want to make rakia or brandy, where you need the aroma and specific taste of the original product, then use only a moonshine still.
Types of moonshine stills and distillation columns
In total, there are two main types of devices for practical moonshine brewing in the world:
- Alcohol-containing vapors are discharged to the side for cooling - directly into the coil or through a steam chamber.
- The vapors are diverted upward into rectification device, where impurities are separated, odors are completely removed and subsequent cooling occurs.
Classic devices are divided according to the cooling system: using a coil or direct-flow, where the cooling element is the refrigerator body.
Columns are divided according to the amount of the final product obtained:
- simple, ensuring the separation of the feedstock into two final products - rectified product and sediment;
- complex - they provide separation into more than two products, columns with the selection of additional fractions in the form of side streams and from special strippers.
There is also a division according to purpose, amount of pressure, principle of operation or organization of contact within the structure.
In addition, columns are divided into complete and incomplete. Incomplete products are divided into two more types:
- A mash or distillation column, which operates on the following principle: alcohol-containing steam enters the upper plate and leaves the cube pure water. Condensation falls out in the refrigerator, but the reflux condenser is not installed.
- In alcohol columns, everything happens in a mirror way: steam is supplied under the lower plate. Alcohol is removed from the upper part, and the remainder with water is removed from the bottom; the reflux condenser performs the function of feeding liquid medium. Such columns are installed on alambiks.
The first ones are not intended for producing pure alcohol, and the second option is not used for producing pure water.
Characteristics of both devices
Everyone knows that the main purpose of a moonshine still is to obtain alcohol-containing liquid from mash through distillation and subsequent purification. Main technical parameters are:
Volume
It is this factor that influences the scale of production at home, so the choice of product is based on this parameter: the more mash, the more liters of raw alcohol that is purified various methods or re-distillation is carried out.
Material
Basically all the details modern models made of food or medical stainless steel. The following brands are used in production:
- AISI 304, due to its fairly high cleaning properties, is used in medicine, on dairy farms and similar factories;
- 430 steel is of low quality, but products made from it can be heated on induction cookers;
- alloys with copper and combinations of steels different brands found in many models of moonshine stills of domestic and foreign production.
Aluminum is still used in home-made devices, but it is almost being replaced by more reliable materials. Coils are made of copper or brass; only elite devices called alambiks, which are used for the production of home-made elite alcohol, are made entirely of copper.
Additional devices
These include a thermometer, an alcohol meter, a steamer, a reflux condenser and others that help control the distillation process. Repeated cleansing gives good result, but it is not carried out in the case when it is necessary to obtain an aromatic drink with a smell.
For clarity, it is better to present the technical characteristics of universal distillation columns in the form of a small table:
All sealing joints in the column are made of high-temperature food-grade silicone with a guaranteed service life of at least 10-20 years, temperatures are allowed up to +150°C.
Advantages and disadvantages
A standard apparatus for the production of moonshine has the following advantages:
- The simplest design, the operating principle is clear to all users, can be made independently without large financial costs.
- There are a large number of recipes that come with the finished model, but you can significantly expand them by studying the recipe on the Internet.
- High reliability of the design and all materials.
- Low cost, which especially affects wide availability for all segments of the population.
Distillation columns have their advantages:
- Obtaining a pure product without odor and foreign impurities.
- The strength of the final product is much higher than that of a simple device.
- It is used to separate alcohol-containing liquid from sugar-based mash, since there are a lot of foreign impurities and odors there.
In comparison, the classic device has more negative features:
- low productivity;
- low percentage of alcohol content - no more than 70%;
- low degree of purification during primary distillation;
- danger if safety precautions are not followed.
Distillation columns have only one drawback - the large height of the structure.
What is better to choose
If we compare the design of a classic moonshine product and a distillation column, the difference is noticeable, and they are used for different purposes. Therefore, your choice will directly depend on your goals, as well as on what you are going to distill:
- For wine mash, as well as those based on berries and fruits, it is better to use a moonshine still.
- For sugar mash, it is better to use a column, since the final product is clean and odorless.
Today, there are models of universal products on sale that can work as a simple distiller or as a powerful distillation column.
Devices made by German manufacturers, which have an additional drawer that is screwed into the distiller, are in particular demand among experienced distillers. For example, the column and the apparatus have the same productivity of 2 l/h, but the product is quite different:
- the density or strength of a classic product is only 60%, and that of a column is 96%;
- The purification level of a distiller is 60 times lower than that of a column.
Moonshine stills are more practical due to their dimensions, and the columns are much taller - the most compact one will be about a meter in height.
When comparing performance different products, then the classic produces 2 liters of raw alcohol per hour, and the column - 2 liters of pure alcohol 96.6%, or in terms of 60% moonshine - 6-7 liters. Therefore, when purchasing, you need to decide what is more important to you - the purity of the final product or the simple use of the product anywhere. Financial capabilities also play an important role.
conclusions
If we talk about the purity of the final product, then distillation columns are head and shoulders above a simple moonshine still, but great importance has a financial side. Each user chooses the necessary model for himself, but we dispassionately state that the classics of the genre still lose to technical progress in the form of a more productive distillation column in terms of basic technical indicators.