Do-it-yourself alcohol distillation column. We make a distillation column with our own hands - step by step instructions
In order to understand the essence of the processes occurring inside the distillation column, we recommend that you refer to the alcohol columns. It discloses the theory of obtaining ethanol, the quality of which is close to the maximum.
Today we will talk about the design of a home rectifier and how this device can be made by hand.
Before you start creating a distillation (packed) column (RC), you need to purchase suitable material. It should be noted right away that all kinds of non-ferrous metals should be deliberately excluded from the design of the device: no copper alloys, no food-grade aluminum and similar materials. Only stainless steel is a chemically inert alloy that is not subject to corrosion and does not emit toxic impurities during the rectification process.
On the pages of FORUMHOUSE you can find a lot of advice regarding the use of copper in the construction of rectifiers and distillers. But if you read, then even more you can find people who disagree with such opinions. The explanation is quite simple: hot alcohol is a very strong solvent. Therefore, the contact of hot alcohol-containing liquids with any non-ferrous metals is highly undesirable and even dangerous to health.
beutiflet FORUMHOUSE user
Only glass, silicone and stainless steel.
Working scheme of the Republic of Kazakhstan
The figure shows a diagram of a standard RK, having dealt with which, you can independently assemble a home rectifier.
Consider the main elements of the design in more detail.
alembic
Any metal container made of stainless steel and having a suitable volume can be used as a distillation cube.
As for the volume: someone uses a regular pressure cooker (with built-in heating), while someone has slightly higher requirements. In general, everyone is guided by their needs.
viktor50 FORUMHOUSE user
The pressure cooker is too small, you need a capacity of at least 15-20 liters. The rectification process takes quite a long time and getting a liter in half a day is not kosher.
As for column heating: the easiest (but not very practical) option is to install the still on an electric or gas stove. The fact is that the column has a relatively large height, so it will be better if the alembic stands on the floor (and not on the stove).
Installing the cube directly on the floor allows electric heating, which makes the design of the RC less cumbersome, and the entire installation - the most convenient in operation.
Timothy1
It is necessary to move from gas to electricity - it is easier to regulate, and the height is added! I cut the heating elements into a flask, connected the voltage regulator from the TV and went ahead.
Be that as it may, when heating the feedstock, smooth power adjustment should be ensured. heating element. Otherwise, the whole idea will be doomed to failure.
Many users, in an attempt to improve the design of the RC, equip the device with automatic control systems, as well as complex regulators. But if you are used to controlling the process on your own (and in the case of a home-made distillation column, at first you will not succeed in a different way), then installing an automatic control system is not an absolute necessity. Until you have sufficient experience in the field of home rectification, a simple power regulator included in the circuit of one of the available electric heaters will be quite enough.
Timothy1
I have three heating elements from a Soviet teapot - 1.25 sq. LATR, shown in the photo, perfectly regulates one heating element.
The rectification process in this case is carried out using one (adjustable) heating element. The remaining 2 are needed exclusively for heating.
If you have already had enough time to enjoy the visual perception of the process, and the lack of time does not allow you to constantly be near the operating RC, then the automation system embedded in the design of the device will allow you to control the process, requiring minimal human participation. Automation allows you to select the contents of the distillation cube, preventing the ingress of tail fractions into the "body" of the product. There are already ready-made technical solutions that can be bought in specialized stores. Such systems, reacting to temperature changes, close the distillate extraction unit at the right time or, conversely, open access to cold water to the reflux condenser.
rectification tsarga
The rectification tsarga includes several components at once:
- Pipe with insulation and nozzle.
- Reflux condenser with distillate extraction unit, water jacket and thermometer.
- Union for connection with the atmosphere.
Given that alcohol vapors are very flammable, a hole for communication with the atmosphere (which is necessarily created at the top of the distillation column) must be equipped with a fitting and a rubber tube. The end of the tube should be lowered into a container of water. This will help prevent the spread of vapors indoors and their ignition.
Consider the design of the listed nodes.
Pipe (packed column)
The process of heat and mass transfer takes place in the lower pipe of the distillation column. In her inner space a special filler is placed, which increases the contact area between the hot vapor and the cooling phlegm. When making the column yourself, it is easiest to use dishwashing sponges made of stainless steel as a filler (nozzle). Sometimes a special twisted wire (also made of stainless steel) is used.
If you use metal washcloths as a filler, then the quality of their manufacture should first be checked. To do this, cut off a piece of washcloth and boil it in a solution of table salt. If instead of stainless steel, another alloy is included in the washcloths, then the products will not be able to withstand such a test and will quickly rust. It is necessary to cut the washcloth. After all, if it has a protective coating, then only in this way can its internal structure be exposed.
The packing density should correspond to the indicator - 250-280 g of packing per liter of the internal volume of the packed column.
The quality of separation of boiling fractions directly depends on the size of the packed tube. Having considered the practical experience of FORUMHOUSE users, we can conclude that the minimum pipe diameter should be 32 mm. In general, the higher the pipe, the better the fraction separation will be. The optimal height of the pipe should correspond to 40-60 of its diameters (at least 20). Outside, the pipe should be insulated with a layer of protective material.
belor44 FORUMHOUSE user
A metal mesh is installed in the inner cavity of the pipe (top and bottom) to hold the filler.
belor44
In my column for NDRF, the filler is washcloths. At the same time, there are nets from a tea strainer. The pressure is stable. A meter column with a diameter of 35 mm produces an under-rectified product with a strength of 96% at a rate of 950 ml per hour. There are no snags.
Bottom and top distillation pipe, as a rule, is equipped with a thread that allows you to connect the unit to a distillation cube and to a dephlegmator.
Dephlegmator
The main purpose of the reflux condenser is the condensation and separation of light fractions that have a lower (relative to reflux) boiling point. In practice, the dephlegmator can have a different design. The simplest to manufacture is recognized as a direct-flow (shirt) type dephlegmator or, as it is also called, a refrigerator-condenser. It consists of two pipes different diameter, between which there is a cooling jacket with running water.
In fact, a straight-through reflux condenser is a stainless steel pipe that is welded into another pipe of the same material (only of a larger diameter). Externally, the device looks like in the image.
The photo shows that the dephlegmator has two fittings (for inlet and outlet of coolant) and a tube for communication with the atmosphere (above). At the same time, at the bottom of the reflux condenser there is a fitting for distillate selection.
To avoid the appearance foreign matter and odors in the composition of the final product, it is recommended to use only silicone tubes for distillate sampling.
The body of the dephlegmator can be made from stainless pipes or from an ordinary food thermos and an additional inner pipe. The diameter of the inner tube is usually equal to the diameter of the packed column. If you do not have access to argon welding, then you can fasten structural elements using an ordinary soldering iron.
The distillate extraction unit, located at the very bottom of the reflux condenser, is a figured washer welded into the inner tube of the device.
In the sampling unit, it is necessary to make holes in advance for the thermometer (if it is planned to be used) and for the sampling tube.
The need to introduce thermometers into the design of the RK is a controversial issue. People "experienced" often do without thermometers at all. At the same time, there are such distillers who, on the contrary, measure the temperature where it needs to be done, and where it is not at all necessary. For example, installing a thermometer in the body of the distillation cube only allows you to control the heating process. That is, by watching it, you can roughly navigate - how much time is left before the column boils.
But there are two constructive nodes in the Republic of Kazakhstan, where temperature control brings tangible practical benefits. These are the dephlegmator outlet pipe and the dephlegmator extraction unit (instead of the extraction unit, the space between the packed column and the dephlegmator can be used to install the thermometer).
If, at the outlet of the reflux condenser, the temperature of running water is allowed to drop below 45 ° C, then the separation of the fractions will not occur very efficiently (due to supercooling of the phlegm). If the temperature is above 55°C, then in the process of sampling the “body”, “tails” will break through the sampling tube.
Controlling the temperature in the extraction unit makes it possible to determine the steam temperature at the outlet of the packed column, and at the same time gives an understanding of which fraction is being separated at the current time. For example, if the temperature of the steam in the extraction unit is within the range of - 77.5-81.5 ° C (depending on atmospheric pressure), then only the “body” of the product will enter the distillate extraction tube.
Siberiafish FORUMHOUSE user
The temperature during the transfer was kept in the range of 78.8-81.3. Before the end, she began to jump.
The inner end of the thermometer tube soldered into the column must be plugged.
In order for the reflux condenser to be evenly cooled from all sides, a screw spiral can be soldered into the cooling jacket, which will set the correct direction of the cooling flow.
But what design of the reflux condenser is offered by one of the users of our portal.
Timothy1 FORUMHOUSE user
I wound two meters of corrugation into the def - it removes 3 liters per hour!
The design of this device is as follows.
In most cases, the corrugation, which passes running water through itself, is wrapped around the inner tube of the dephlegmator (it is not shown in the figure). However, this approach does not always allow efficient heat transfer to be achieved. Feasibility of implementation similar design can only be determined practically.
In practice, you can find dephlegmators of the most diverse designs (including horizontal devices). We have described only the most common.
Dephlegmator dimensions
The main quantity that determines the dimensions of the device is the area of contact of the steam with the cooled surface. This value is often determined empirically. It depends on the power supplied to the column and on the temperature of the coolant.
Timothy1
The distillation column I made two weeks ago produces 1200 ml of alcohol per hour. You can do more, but there is not enough cooling! The input power during acceleration is 3.5 kW, during the stage - 1.25 kW.
The product yield is always proportional to the input power. For example, if the power supplied to the cube (in the process of rectification) is 700 W, then the maximum productivity of the column will be 700 ml/hour (in practice, at this power we have 300-500 ml/hour). The area of the reflux condenser with such a performance should be equal to - 200-300 cm². Such an area is possessed by the inner tube of the reflux condenser, which has a length of 300 mm and a thickness of 32 mm.
Doobik FORUMHOUSE user
The rate of distillation primarily depends on the strength of the heating. If the stove can boil 1 liter per hour out of the mash, then no matter what the apparatus, you will not get 2 liters per hour. The purer and stronger the product, the slower the distillation. The apparatus itself can slow down the process in only one case - the low power of the reflux condenser, that is, when it is necessary to reduce the heating for the normal operation of the apparatus. The larger the diameter, the larger the heat transfer area, and the better the heat removal.
From the foregoing, we can conclude that it is better to have a reflux condenser with dimensions exceeding the calculated ones. After all, an excess cooling area will never lead to a cessation of condensate formation, and, consequently, to a cessation of rectification.
By the way, on the Internet you can find a calculator for calculating the reflux condenser, which will help you navigate the dimensions of the manufactured device.
Fridge
As a cooler for the sampled distillate, you can use a laboratory cooler, which is usually purchased at a laboratory glassware store.
In this case, the device can be made independently - according to the principle of a shirt-type dephlegmator (only the refrigerator will be much smaller in size). For this, again, stainless steel tubes of small diameter should be used. The length of the refrigerator should approximately equal the length of the reflux condenser.
In order to regulate the rate of distillate withdrawal or to stop (start) extraction in a timely manner, the distillate withdrawal tube should be equipped with a stopcock or a clamp (for example, from a dropper). The location of the clamp is indicated on the general diagram of the RK.
The cooling cavities of the refrigerator and dephlegmator are interconnected in the following sequence: bottom of the refrigerator - refrigerator - top of the refrigerator - top of the dephlegmator - dephlegmator - bottom of the dephlegmator - sewerage. Simply put, a series connection of pipes is used, while water is supplied to the dephlegmator already slightly heated.
The temperature of the cooling water in the dephlegmator, as we already know, must correspond to certain values (approximately - 45-55 ° C). And additional taps for adjusting the water flow will help us achieve the required indicators. The valve from the gas welding torch regulates the flow most finely.
Distillate distillation sequence
Consider the sequence of work with our distillation column. First of all, we dilute raw alcohol (obtained after preliminary distillation of mash) tap water to a fortress - 30% ... 40% (there is no consensus on this indicator, but the lower it is, the less likely it is to accidentally ignite). Then we pour it into the distillation cube, assemble the distillation column and fit it to the distillation tank.
The column, under no circumstances, should not deviate from the vertical level. Otherwise, the quality of the final product will noticeably suffer.
After the RC is installed, you can start heating the contents of the cube. The distillate tap must be closed. At the moment when the steam temperature in the reflux condenser begins to rise sharply, it is necessary to reduce the power supplied to the column to a minimum (the temperature at this moment can quickly reach 70-78 ° C, which is associated with a sharp rise in vapor through the packed part of the column). In this position, the device should be left for 30 minutes. This is necessary in order for the RC to warm up, and the process of heat and mass transfer to begin inside it. The temperature in the upper part of the RC may then fall.
After the specified time, we turn on the water supply to the refrigerator (and to the reflux condenser) and begin the selection of “heads”. We repeat once again that you can’t drink “heads”!
The end of the selection of "heads" can be determined by several signs: temperature stabilization - around 78 ° C and a change in the organoleptic characteristics of the selected distillate (the distillate begins to smell of alcohol).
After the selection of the "heads", you can begin the selection of the "body": increase the power of the column and adjust the water temperature in the dephlegmator (45°C - 55°C).
We enjoy the process until the “tails” are cut off. The beginning of the tail fractions condensation can be judged by the increase in temperature in the reflux condenser (up to about 85°C) and the appearance of the smell of fuselage in the sampled distillate. On this, the process of rectification will be considered completed. Tailing fractions can be selected for use in the process of subsequent hauls, or simply disposed of. It's up to you.
If you are familiar with in practice, then we invite you to take part in the discussion of issues related to this fascinating topic. If you are accustomed to eating no less sophisticated snacks along with exquisite drinks, then this article will teach you to endlessly surprise guests with the unusual taste of cooked dishes.
The purpose of the article is to analyze the theoretical and some practical aspects of the work of a home distillation column aimed at obtaining ethyl alcohol, as well as dispel the most common myths on the Internet and clarify the points that equipment sellers are “silent about”.
Alcohol rectification– separation of a multicomponent alcohol-containing mixture into pure fractions (ethyl and methyl alcohols, water, fusel oils, aldehydes, and others) having different boiling points by repeated evaporation of the liquid and condensation of steam on contact devices (plates or nozzles) in special counterflow tower apparatuses.
From a physical point of view, rectification is possible, since initially the concentration of individual components of the mixture in the vapor and liquid phases is different, but the system tends to equilibrium - the same pressure, temperature and concentration of all substances in each phase. Upon contact with a liquid, the vapor is enriched with volatile (low-boiling) components, while the liquid, in turn, is enriched with low-volatile (high-boiling) ones. Simultaneously with enrichment, heat exchange takes place.
circuit diagram The moment of contact (interaction of flows) between vapor and liquid is called the process of heat and mass transfer.
Due to the different directions of movements (steam rises, and the liquid flows down), after the system reaches equilibrium in the upper part of the distillation column, it is possible to separately select practically pure components that were part of the mixture. First, substances with a lower boiling point (aldehydes, esters and alcohols) come out, then with a high one (fusel oils).
A state of balance. Appears at the very boundary of the phase separation. This can only be achieved if two conditions are met simultaneously:
- Equal pressure of each individual component of the mixture.
- The temperature and concentration of substances in both phases (vapor and liquid) is the same.
The more often the system comes into equilibrium, the more efficient the heat and mass transfer and the separation of the mixture into individual components.
Difference between distillation and rectification
As you can see from the graph, out of 10% alcohol solution(mash) you can get moonshine 40%, and during the second distillation of this mixture, a 60-degree distillate will come out, with the third - 70%. The following intervals are possible: 10-40; 40-60; 60-70; 70-75 and so on up to a maximum of 96%.
Theoretically, to obtain pure alcohol, 9-10 successive distillations per moonshine still. In practice, distillation of alcohol-containing liquids with a concentration above 20-30% is explosive, moreover, due to the high energy and time costs, it is economically unprofitable.
From this point of view, the rectification of alcohol is a minimum of 9-10 simultaneous, stepwise distillations that occur on different contact elements of the column (packings or plates) along the entire height.
| difference | Distillation | Rectification |
| Organoleptics of the drink | Keeps aroma and taste of initial raw materials. | It turns out pure alcohol without smell and taste (the problem has a solution). |
| Fortress at the exit | Depends on the number of distillations and the design of the apparatus (usually 40-65%). | Up to 96%. |
| The degree of separation into fractions | Low, substances even with different boiling points are mixed, it is impossible to fix this. | High, pure substances can be isolated (only with different boiling points). |
| Ability to remove harmful substances | Low or medium. To improve the quality, a minimum of two distillations with separation into fractions in at least one of them is required. | High, with the right approach, all harmful substances are cut off. |
| Alcohol loss | High. Even with the right approach, you can extract up to 80% of the total amount, while maintaining an acceptable quality. | Low. Theoretically, it is possible to extract all the ethyl alcohol without loss of quality. In practice, at least 1-3% losses. |
| The complexity of the technology for implementation at home | Low and medium. Even the most primitive apparatus with a coil is suitable. Equipment improvements are possible. The technology of distillation is simple and clear. A moonshine still does not usually take up much space in working order. | High. Special equipment is required, which is impossible to manufacture without knowledge and experience. The process is more difficult to understand, preliminary at least theoretical preparation is needed. The column takes up more space (especially in height). |
| Danger (compared to each other), both processes are flammable and explosive. | Due to the simplicity of the moonshine still, distillation is somewhat safer (subjective opinion of the author of the article). | Due to the complex equipment, when working with which there is a risk of making more mistakes, rectification is more dangerous. |
Operation of the distillation column
Distillation column- a device designed to separate a multicomponent liquid mixture into separate fractions according to the boiling point. It is a cylinder of constant or variable section, inside which there are contact elements - plates or nozzles.
Also, almost every column has auxiliary units for supplying the initial mixture (raw alcohol), controlling the rectification process (thermometers, automation) and distillate extraction - a module in which the vapor of a certain substance extracted from the system is condensed and then taken out.
One of the most common home designs Raw alcohol- a product of the distillation of mash by the classical distillation method, which can be "filled" into a distillation column. In fact, this is moonshine with a strength of 35-45 degrees.
Reflux- steam condensed in the dephlegmator, flowing down the walls of the column.
Phlegm number- the ratio of the amount of reflux to the mass of the sampled distillate. There are three streams in the alcohol distillation column: steam, phlegm and distillate (end goal). At the beginning of the process, the distillate is not withdrawn so that there is enough reflux in the column for heat and mass transfer. Then part of the alcohol vapor is condensed and taken from the column, and the remaining alcohol vapor continues to create a reflux flow, ensuring normal operation.
For the operation of most installations, the reflux ratio must be at least 3, that is, 25% of the distillate is taken, the rest is needed in the column for irrigating the contact elements. General rule: The slower the alcohol is withdrawn, the higher the quality.
Distillation column contact devices (trays and packings)
They are responsible for the multiple and simultaneous separation of the mixture into liquid and vapor, followed by the condensation of vapor into a liquid - the achievement of an equilibrium state in the column. Ceteris paribus, the more contact devices in the design, the more effective distillation in terms of alcohol purification, since the surface of interaction of phases increases, which intensifies the entire heat and mass transfer.
theoretical plate- one cycle of exit from the equilibrium state with its repeated achievement. To obtain high-quality alcohol, a minimum of 25-30 theoretical plates is required.
physical plate- a real working device. The vapor passes through the liquid layer in the plate in the form of many bubbles, creating an extensive contact surface. In the classical design, the physical plate provides about half of the conditions for reaching one equilibrium state. Therefore, for the normal operation of the distillation column, two times more physical plates are required than the theoretical (calculated) minimum - 50-60 pieces.
Nozzles. Often, plates are placed only on industrial installations. In laboratory and home distillation columns, nozzles are used as contact elements - specially twisted copper (or steel) wire or dishwashing nets. In this case, the phlegm flows down in a thin stream over the entire surface of the nozzle, providing maximum area steam contact.
Washcloth nozzles are the most practical There are a lot of structures. The disadvantage of home-made wire nozzles is the possible damage to the material (blackening, rust), factory counterparts are devoid of such problems.
Properties of distillation column
Material and dimensions. The column cylinder, nozzles, cube and distillers must be made of a food-grade, stainless, heat-safe (expands evenly) alloy. In home-made designs, cans and pressure cookers are most often used as a cube.
The minimum length of the pipe of a home distillation column is 120-150 cm, diameter is 30-40 mm.
heating system. In the process of rectification, it is very important to control and quickly adjust the heating power. Therefore, the most successful solution is heating with the help of heating elements built into lower part Cuba. The supply of heat through a gas stove is not recommended, because it does not allow you to quickly change the temperature range (high inertia of the system).
Process control. During rectification, it is important to follow the instructions of the column manufacturer, which must indicate the features of operation, heating power, reflux ratio and model performance.
The thermometer allows precise control of the sampling process It is very difficult to control the rectification process without two simple devices - a thermometer (helps determine the correct degree of heating) and an alcohol meter (measures the strength of the resulting alcohol).
Performance. It does not depend on the size of the column, since the higher the side (pipe), the more physical plates are inside, therefore, the cleaning is better. The performance is affected by the heating power, which determines the speed of steam and reflux flows. But with an excess of supplied power, the column chokes (stops working).
The average performance of home distillation columns is 1 liter per hour with a heating power of 1 kW.
Influence of pressure. The boiling point of liquids depends on pressure. For successful distillation of alcohol, the pressure at the top of the column should be close to atmospheric - 720-780 mm Hg. Otherwise, when the pressure decreases, the vapor density will decrease and the evaporation rate will increase, which may cause flooding of the column. If the pressure is too high, the evaporation rate drops, making the operation of the device inefficient (there is no separation of the mixture into fractions). To maintain the correct pressure, each distillation column is equipped with an atmospheric connection tube.
About the possibility of self-made assembly. Theoretically, a distillation column is not a very complex device. Designs are successfully implemented by craftsmen at home.
But in practice, without understanding the physical foundations of the rectification process, correct calculations of equipment parameters, selection of materials and high-quality assembly of units, the use of a home-made distillation column turns into a dangerous occupation. Even one mistake can lead to fire, explosion or burns.
In terms of safety, factory columns that have been tested (have supporting documentation) are more reliable, and they are also supplied with instructions (must be detailed). The risk of a critical situation comes down to only two factors - proper assembly and operation according to the instructions, but this is a problem for almost all household appliances, and not just columns or moonshine stills.
The principle of operation of the distillation column
The cube is filled with a maximum of 2/3 of the volume. Before turning on the installation, it is imperative to check the tightness of the connections and assemblies, shut off the distillate extraction unit and supply cooling water. Only after that you can start heating the cube.
The optimal strength of the alcohol-containing mixture fed into the column is 35-45%. That is, in any case, distillation of the mash is required before rectification. The resulting product (raw alcohol) is then processed on a column, obtaining almost pure alcohol.
This means that a home distillation column is not a complete replacement for the classic moonshine still (distiller) and can only be considered as an additional purification step that replaces re-distillation (second distillation) in a better quality, but leveling the organoleptic properties of the drink.
In fairness, I note that most modern models of distillation columns involve working in the moonshine still mode. To proceed to distillation, it is only necessary to close the connection to the atmosphere and open the distillate selection unit.
If both nozzles are closed at the same time, then the heated column may explode due to excess pressure! Don't make these mistakes!
In industrial plants continuous action often the mash is distilled immediately, but this is possible due to its gigantic size and design features. For example, a pipe 80 meters high and 6 meters in diameter is considered a standard, in which many more contact elements are installed than on distillation columns for a house.
Size matters. The possibilities of distilleries in terms of cleaning the cube are greater than with home distillation After switching on, the liquid in the cube is brought to a boil by the heater. The resulting steam rises up the column, then enters the reflux condenser, where it condenses (phlegm appears) and returns in liquid form to the lower part of the column along the pipe walls, on the way back contacting the rising steam on plates or nozzles. Under the action of the heater, the phlegm again becomes steam, and the steam at the top is again condensed by a dephlegmator. The process becomes cyclic, both streams are in continuous contact with each other.
After stabilization (steam and phlegm are sufficient for an equilibrium state), pure (separated) fractions with the lowest boiling point (methyl alcohol, acetaldehyde, ethers, ethyl alcohol) accumulate in the upper part of the column, with the highest (fusel oils) at the bottom. As the selection of the lower fractions gradually rise up the column.
In most cases, a column in which the temperature does not change for 10 minutes (total warm-up time is 20-60 minutes) is considered stable (it is possible to start sampling). Up to this point, the device works "on its own", creating flows of steam and phlegm that tend to balance. After stabilization, the selection of the head fraction containing harmful substances begins: esters, aldehydes and methyl alcohol.
The distillation column does not eliminate the need to separate the output into fractions. As in the case of a conventional moonshine still, you have to assemble the “head”, “body” and “tail”. The difference is only in the purity of the output. During rectification, the fractions are not “lubricated” - substances with a close, but at least a tenth of a degree, different boiling point do not intersect, therefore, when the “body” is selected, almost pure alcohol is obtained. During conventional distillation, it is physically impossible to separate the yield into fractions consisting of only one substance, no matter what design is used.
If the column is brought to the optimal mode of operation, then there are no difficulties during the selection of the “body”, since the temperature is stable all the time.
The lower fractions (“tails”) are selected during rectification, guided by temperature or smell, but unlike distillation, these substances do not contain alcohol.
Return to alcohol of organoleptic properties. Often, "tails" are required to return the "soul" to rectified alcohol - the aroma and taste of the raw material, for example, apples or grapes. After the process is completed, a certain amount of collected tail fractions is added to pure alcohol. The concentration is calculated empirically by experimenting on a small amount of product.
The advantage of rectification is the ability to extract almost all the alcohol contained in the liquid without losing its quality. This means that the “heads” and “tails” obtained on a moonshine still can be processed on a distillation column and ethyl alcohol safe for health can be obtained.
Flooding of distillation column
Each design has a maximum speed of steam movement, after which the flow of reflux in the cube first slows down, and then stops altogether. The liquid accumulates in the distillation part of the column and "flooding" occurs - the termination of the heat and mass transfer process. Inside there is a sharp pressure drop, extraneous noise or gurgling appears.
Causes of flooding of the distillation column:
- exceeding the permissible heating power (most common);
- clogging the bottom of the device and overflowing the cube;
- very low Atmosphere pressure(typical for highlands);
- the voltage in the network is higher than 220V - as a result, the power of the heating elements increases;
- design errors and failures.
§ 13.2 Distillation columns: their design and operation
As mentioned above, rectification is carried out in special apparatus - distillation columns, which are the main elements of distillation plants.
rectification process can be carried out periodically and continuously, regardless of the type and design of distillation columns. Consider the process of continuous distillation, which is used to separate liquid mixtures in industry.
Distillation column- vertical cylindrical apparatus with welded (or prefabricated) body, in which mass and heat exchange devices (horizontal plates 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 the deaf steam located in the coil or in the shell-and-tube heater-boiler. An integral part of the distillation column is a dephlegmator 7, designed to condense the steam leaving the column.
Distillation plate column works as follows. The cube is constantly heated, and the bottom liquid boils. The steam formed in the cube rises up the column. The initial mixture to be separated is preheated to boiling. It is fed to the 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 down to the underlying plates, interacting on its way with the steam moving from bottom to top. As a result of this interaction, the vapor is enriched in the volatile component, and the liquid flowing down, being depleted in this component, is enriched in the hardly volatile component. In the lower part of the column, the process of extraction (exhaustion) of the volatile component from the initial mixture and its transition to steam takes place. Some part of the finished product (rectified) is supplied to the top of the column for irrigation.
The liquid entering the top of the column for irrigation and flowing down the column is called phlegm. Steam, interacting with reflux on all plates of the upper part of the column, is enriched (strengthened) with a volatile component. The steam leaving the column is sent to the dephlegmator 7, in which it is condensed. The resulting distillate is divided into two streams: one in the form of 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 tray distillation column is the tray, since it is on it that the vapor interacts with the liquid. On 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 nozzles 2 and drain pipes 5. Steam nozzles are designed to pass the vapors rising from the bottom plate. Through the drain pipes, the liquid flows from the overlying plate to the underlying one. A cap is mounted on each steam nozzle 3, by means of which the vapors are directed into the liquid, bubbled through it, cooled and partially condensed. The bottom of each tray is heated by the vapors of the underlying tray. In addition, partial condensation of steam releases heat. Due to this heat, the liquid on each plate boils, forming its own vapors, which mix with the vapors from the underlying plate. The liquid level on the plate is maintained by means of drain pipes.
Rice. 13.3. Scheme of a distillation column: / - body; 2 - plates; 3 - cube; 4, 6 - exhaustive and strengthening parts of the column; 5 - nutritious plate; 7 - dephlegmator
The processes occurring on the plate can be described as follows (see Fig. 13.4). Let the vapors of the composition L from the lower plate enter the plate, and the liquid of the composition AT. As a result of the interaction of steam BUT with liquid AT(steam, bubbling through the liquid, partially evaporates it, and partially condenses itself) a new vapor of the composition is formed FROM and new composition fluid D, being in balance. As a result of the work of the plate, new steam FROM richer in volatile matter compared to the steam coming from the bottom plate BUT, that is, on a plate of steam FROM enriched with volatile matter. New fluid D, on the contrary, it became poorer in volatile matter compared to the liquid that came from the upper plate AT, that is, on a plate, the liquid is depleted in the volatile component and enriched in the non-volatile component. In short, the work of the plate is reduced to the enrichment of the vapor and the depletion of the liquid with a highly volatile component.
Rice. 13.4. Scheme of the device and operation of the cap plate: / - the bottom of the plate; 2 - steam pipe;
3 - cap; 4 - column body; 5 - drain pipe
Rice. 13.5. The image of the work of a distillation plate on the diagram at-x: 1- equilibrium curve;
2 - line of working concentrations
A plate on which a state of equilibrium is reached between the vapors rising from it and the liquid flowing down is called theoretical. In real conditions, due to the short-term interaction of vapor with liquid on the plates, an equilibrium state is not reached. The separation of the mixture on a real plate is less intense than on a theoretical one. Therefore, to perform: the operation of one theoretical plate requires more than one real plate.
On fig. 13.5 shows the operation of a distillation plate using a diagram at-X. The theoretical plate corresponds to a hatched rectangular triangle, the legs of which are the magnitude of 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, equal to x B - x D . The segments corresponding to the indicated changes in concentration converge on the equilibrium curve. This assumes that the phases leaving the plate are in equilibrium. However, in reality, the state of equilibrium is not reached, and the segments of the change in concentrations 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 plates of distillation columns are very diverse. Let's briefly consider the main ones.
Columns with bubble caps widely used in industry. The use of caps ensures good contact between vapor and liquid, efficient mixing on the plate and intensive mass transfer between the phases. The shape of caps can be round, polyhedral and rectangular, plates - single and multi-cap.
A plate with grooved caps is shown in fig. 13.6. The steam from the lower plate passes through the gaps and enters the upper (inverted) troughs, which direct it to the lower troughs filled with liquid. Here, steam bubbles through the liquid, which provides an intensive 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 holes of small diameter (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 to the underlying plate. Therefore, sieve trays require appropriate regulation and are very sensitive to regime changes. In the case of a decrease in vapor pressure, the liquid from the sieve plates goes down. Sieve trays are sensitive to impurities (precipitation) that can clog holes, creating conditions for the formation of increased pressures. All this limits their application.
Packed columns(Fig. 13.8) are distinguished by the fact that in them the role of plates is performed by the so-called “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 as nozzles.
Steam enters the lower part of the column from an external boiler and moves up the column towards the flowing liquid. Distributing over a large surface formed by packed bodies, the vapor intensively contacts the liquid, exchanging components. The packing must have a large surface area per unit volume, provide low hydraulic resistance, be resistant to the chemical effects of liquid and steam, have high mechanical strength, and be of low cost.
Packed columns have low hydraulic resistance and are easy to use: they are easily emptied, washed, blown, and cleaned.
Rice. 13.6. Plate with grooved caps: a- general form; b- lengthwise cut; in- diagram of the plate
Rice. 13.7. Scheme of the sieve plate device: / - column body; 2 - plate; 3 - drain pipe; 4 - hydraulic lock; 5 - holes
Rice. 13.8. Diagram of a packed distillation column: 1 - frame; 2 - input of the initial mixture; 3 - steam; 4 - irrigation; 5 - lattice; 6 - nozzle; 7-removal of the high-boiling product j-. 8 - remote boiler
Sooner or later, almost every homemade alcohol lover thinks about purchasing or manufacturing a distillation column (RK) - a device for obtaining pure alcohol. You need to start with a comprehensive calculation of the basic parameters: power, height, drawer diameter, cube volume, etc. This information will be useful both for those who want to make all the elements with their own hands, and for those who are going to buy a ready-made distillation column (it will help you make a choice and check the seller). Without affecting design features individual nodes, we will consider general principles building a balanced system for rectification at home.
Column operation scheme Characteristics of the pipe (tsargi) and nozzles
Material. The pipe largely determines the parameters of the distillation column and the requirements for all units of the apparatus. The material for the manufacture of the side is chromium-nickel stainless steel - "food" stainless steel.
Due to chemical neutrality, food grade stainless steel does not affect the composition of the product, which is required. Raw is distilled into alcohol from sugar mash or distillation waste (“heads” and “tails”), therefore the main purpose of rectification is to maximize the output of impurities, and not change the organoleptic properties of alcohol in one direction or another. It is inappropriate to use copper in classic distillation columns, since this material slightly changes chemical composition drink and is suitable for the production of a distiller (ordinary moonshine still) or beer column(a special case of rectification).
A disassembled column pipe with a nozzle installed in one of the drawers Thickness. The drawer side is made of stainless steel pipe with a wall thickness of 1-1.5 mm. A thicker wall is not needed, as this will increase the cost and weight of the structure without obtaining any advantages.
Nozzle options. It is not correct to talk about the characteristics of the column without reference to the packing. When rectifying at home, nozzles with a contact surface area of 1.5 to 4 square meters are used. m/liter. With an increase in the area of the contact surface, the separating ability also increases, but the productivity decreases. Reducing the area leads to a decrease in the separating and strengthening ability.
The productivity of the column initially increases, but then, to maintain the strength of the output, the operator is forced to lower the selection rate. This means that there is some optimal size nozzles, which depends on the diameter of the column and will allow you to achieve the best combination of parameters.
The dimensions of the spiral prismatic packing (SPN) should be less than the inner diameter of the column by about 12-15 times. For a pipe diameter of 50 mm - 3.5x3.5x0.25 mm, for 40 - 3x3x0.25 mm, and for 32 and 28 - 2x2x0.25 mm.
Depending on the tasks, it is advisable to use different nozzles. For example, when obtaining fortified distillates, copper rings with a diameter and height of 10 mm are often used. It is clear that in this case the goal is not the separating and strengthening ability of the system, but a completely different criterion - the catalytic ability of copper to eliminate sulfur compounds from alcohol.
Variants of spiral prismatic nozzles You should not limit your arsenal to one, even the best nozzle, there are simply no such ones. There are the most suitable for each specific task.
Even a small change in the column diameter seriously affects the parameters. To evaluate, it is enough to remember that the nominal power (W) and productivity (ml / h) are numerically equal to the area cross section columns (sq. mm), and therefore proportional to the square of the diameter. Pay attention to this when choosing a drawer, always consider the inner diameter and compare options using it.
Dependence of power on pipe diameter
Pipe height. To ensure good holding and separating capacity, regardless of diameter, the height of the distillation column should be from 1 to 1.5 m. If less, there will not be enough space for accumulated during work fusel oils, as a result, the fuselage will begin to break into the selection. Another drawback is that the heads will not be clearly divided into fractions. If the pipe height is greater, this will not lead to a significant improvement in the separating and holding capacity of the system, but will increase the driving time, as well as the number of "heads" and "headrests". decreases. The effect of increasing the pipe from 50 cm to 60 cm is an order of magnitude higher than from 140 cm to 150 cm.
The volume of the cube for the distillation column
In order to increase the yield of high-quality alcohol, but to prevent overfilling of the fusel column, the bulk (filling) of raw alcohol in the cube is limited in the range of 10-20 packing volumes. For columns 1.5 m high and 50 mm in diameter - 30-60 l, 40 mm - 17-34 l, 32 mm - 10-20 l, 28 mm - 7-14 l.
Taking into account the filling of the cube by 2/3 of the volume, a 40-80 liter container is suitable for a column with an inner diameter of a tsarga of 50 mm, a 30-50 liter container for 40 mm, a 20-30 liter cube for 32 mm, and a pressure cooker for 28 mm.
When using a cube with a volume closer to the lower limit of the recommended range, you can safely remove one side and reduce the height to 1-1.2 meters. As a result, there will be relatively little fuselage for a breakthrough in the selection, but the volume of “head restraints” will noticeably decrease.
Source and power of column heating
Plate type. The moonshine past haunts many beginners who believe that if they previously used a gas, induction or conventional electric stove to heat the moonshine, then you can leave this source for the column.
The rectification process is significantly different from distillation, everything is much more complicated and the fire will not work. It is necessary to ensure smooth adjustment and stability of the supplied heating power.
Electric stoves operating on a thermostat in start-stop mode are not used, because as soon as a short-term power outage occurs, the steam will stop going into the column, and the phlegm will collapse into a cube. In this case, you will have to start rectification again - with the work of the column for yourself and the selection of "heads".
An induction cooker is an extremely rough apparatus with a step change in power of 100-200 W, and during rectification, you need to change the power smoothly, literally by 5-10 W. Yes, and it is unlikely that it will be possible to stabilize the heating, regardless of the voltage fluctuation at the input.
A gas stove with 40% raw alcohol poured into a cube and a 96-degree product at the outlet is a mortal danger, not to mention fluctuations in the heating temperature.
The optimal solution is to embed a heating element of the required power into the cube, and use a relay with output voltage stabilization, for example, RM-2 16A, to adjust. You can take analogs. The main thing is to get a stabilized voltage at the output and the ability to smoothly change the heating temperature by 5-10 watts.
Power supplied. In order to heat the cube in an acceptable time, one must proceed from a power of 1 kW per 10 liters of raw alcohol. This means that for a 50 l cube filled with 40 liters, a minimum of 4 kW is required, 40 l - 3 kW, 30 l - 2-2.5 kW, 20 l - 1.5 kW.
With the same volume, cubes can be low and wide, narrow and high. When choosing a suitable container, it should be taken into account that the cube is often used not only for rectification, but also for distillation, therefore, they proceed from the most severe conditions so that the input power does not lead to rapid foaming with splashes from the cube into the steam pipeline.
It has been experimentally established that at a heating element placement depth of about 40-50 cm, normal boiling occurs if per 1 sq. cm bulk mirrors account for no more than 4-5 watts of power. With a decrease in depth, the allowable power increases, and with an increase, it decreases.
There are other factors that affect the nature of boiling: the density, viscosity and surface tension of the liquid. It happens that emissions occur at the end of the mash distillation, when the density increases. Therefore, conducting the rectification process at the border of the permitted range is always fraught with trouble.
Common cylindrical cubes have a diameter of 26, 32, 40 cm. Based on the allowable power for the surface area of the cube bulk mirror of 26 cm, the cube will work normally with a heating power of up to 2.5 kW, for 30 cm - 3.5 kW, 40 cm - 5 kW .
The third factor that determines the heating power is the use of one of the tsarg columns without a nozzle as a dry steamer to combat splashing. To do this, it is necessary that the steam velocity in the pipe does not exceed 1 m / s, at 2-3 m / s the protective effect weakens, and at large values the steam will drive the phlegm up the pipe and throw it into the selection.
Formula for calculating steam speed:
V \u003d N * 750 / S (m / s),
- N – power, kW;
- 750 - vaporization (cub. cm / sec kW);
- S is the cross-sectional area of the column (sq. mm).
A pipe with a diameter of 50 mm will cope with spray when heated up to 4 kW, 40-42 mm - up to 3 kW, 38 - up to 2 kW, 32 - up to 1.5 kW.
Based on the above considerations, we select the volume, cube dimensions, heating and distillation power. All these parameters are coordinated with the diameter and height of the column.
Calculation of the parameters of the dephlegmator of the distillation column
The power of the reflux condenser is determined depending on the type of distillation column. If we build a column with liquid extraction or steam below the dephlegmator, then required power must not be less than the nominal power of the column. Usually in these cases, a Dimroth refrigerator with a utilization power of 4-5 watts per 1 sq. see surface.
If the steam extraction column is higher than the reflux condenser, then the calculated capacity is 2/3 of the nominal one. In this case, you can use Dimroth or "shirt". The utilization power of the shirt is lower than that of the dimroth and is about 2 watts per square centimeter.
An example of a Dimroth cooler for a column Further, everything is simple: we divide the rated power by the utilization one. For example, for a column with an inner diameter of 50 mm: 1950/5= 390 sq. cm area of Dimroth or 975 sq. see shirt. This means that the Dimrot refrigerator can be made from a 6x1 mm tube 487 / (0.6 * 3.14) = 2.58 cm long for the first option, taking into account the safety factor of 3 meters. For the second option, we multiply by two thirds: 258 * 2/3 = 172 cm, taking into account the safety factor of 2 meters.
Column shirt 52 x 1 - 975 / 5.2 / 3.14 \u003d 59 cm * 2/3 \u003d 39 cm. But this is for rooms with high ceilings.
"Shirtman" Calculation of a once-through refrigerator
If the straight-through is used as an aftercooler in a distillation column with liquid withdrawal, then choose the smallest and most compact option. Enough power is 30-40% of the nominal power of the column.
A direct-flow refrigerator is made without a spiral in the gap between the jacket and the inner pipe, then the selection is started into the jacket, and the cooling water is supplied through the central pipe. In this case, the shirt is welded onto the water supply pipe to the dephlegmator. This is a small "pencil" about 30 cm long.
But if the same straight-through is used both for distillation and for rectification, being a universal unit, they do not proceed from the need of the Republic of Kazakhstan, but from the maximum heating power during distillation.
To create a turbulent steam flow in the refrigerator, which makes it possible to ensure a heat transfer rate of at least 10 watts / sq. cm, it is necessary to provide a steam speed of about 10-20 m / s.
The range of possible diameters is quite wide. The minimum diameter is determined from the conditions of not creating a large overpressure in the cube (no more than 50 mm of water column), but the maximum by calculating the Reynolds number, based on the minimum speed and maximum coefficient of kinematic viscosity of vapors.
Possible design of a once-through refrigerator In order not to go into unnecessary details, here is the most common definition: “In order for the turbulent mode of steam movement to be maintained in the pipe, it is sufficient that the inner diameter (in millimeters) be no more than 6 times the heating power (in kilowatts).”
To prevent the water jacket from airing, it is necessary to maintain a linear water velocity of at least 11 cm / s, but an excessive increase in speed will require high pressure in the water supply. Therefore, the range from 12 to 20 cm/s is considered optimal.
To condense the steam and cool the condensate to an acceptable temperature, water must be supplied at 20°C at a rate of about 4.8 cc/s (17 liters per hour) for every kilowatt of power input. In this case, the water will heat up by 50 degrees - up to 70 ° C. Naturally, less water will be needed in winter, and when using autonomous cooling systems, about one and a half times more.
Based on the previous data, the annulus cross-sectional area and the inside diameter of the jacket can be calculated. It is necessary to take into account the available assortment of pipes. Calculations and practice have shown that a gap of 1-1.5 mm is quite sufficient to comply with all necessary conditions. This corresponds to pairs of pipes: 10x1 - 14x1, 12x1 - 16x1, 14x1 - 18x1, 16x1 - 20x1 and 20x1 - 25x1.5, which cover the entire power range used at home.
There is another important detail of the straight-through - a spiral wound on a steam pipe. Such a spiral is made of wire with a diameter that provides a gap of 0.2-0.3 mm to the inner surface of the shirt. It is wound with a step equal to 2-3 diameters of the steam pipe. The main purpose is to center the steam pipe, in which, during operation, the temperature is higher than in the jacket pipe. This means that as a result of thermal expansion, the steam pipe lengthens and bends, leaning against the jacket, dead zones appear that are not washed by cooling water, as a result, the efficiency of the refrigerator drops sharply. Additional advantages of spiral winding are the lengthening of the path and the creation of turbulence in the cooling water flow.
A well-made straight-through can utilize up to 15 watts / sq. cm of the heat exchange area, which is confirmed by experience. To determine the length of the cooled part of the direct flow, we use a rated power of 10 W / sq. cm (100 sq. cm / kW).
The required heat exchange area is equal to the heating power in kilowatts multiplied by 100:
S = P * 100 (sq. cm).
Steam pipe outer circumference:
Locr = 3.14 * D.
Cooling jacket height:
H = S / Len.
General calculation formula:
H = 3183 * P / D (power in kW, height and outer diameter of the steam pipe in millimeters).
An example of the calculation of a straight pipe
Heating power - 2 kW.
It is possible to use pipes 12x1 and 14x1.
Sectional areas - 78.5 and 113 square meters. mm.
Steam volume - 750 * 2 \u003d 1500 cubic meters. cm / s.
Steam velocities in pipes: 19.1 and 13.2 m/s.
The 14x1 pipe looks preferable, as it allows you to have a power margin, while remaining in the recommended steam speed range.
The steam pipe for the shirt is 18x1, the annular gap will be 1 mm.
Water supply rate: 4.8 * 2= 9.6 cm3/s.
Annular gap area - 3.14 / 4 * (16 * 16 - 14 * 14) = 47.1 sq. mm = 0.471 sq. cm.
Linear speed - 9.6 / 0.471 = 20 cm/s - the value remains within the recommended limits.
If the annular gap were 1.5 mm - 13 cm / s. If 2 mm, then the linear speed would drop to 9.6 cm / s and water would have to be supplied above the nominal volume, solely so that the refrigerator does not air up - a waste of money.
Shirt height - 3183 * 2 / 14 = 454 mm or 45 cm. The safety factor is not needed, everything is taken into account.
Result: 14x1-18x1 with a height of the cooled part 45 cm, nominal water flow - 9.6 cubic meters. cm/s or 34.5 liters per hour.
With a rated heating power of 2 kW, the refrigerator will produce 4 liters of alcohol per hour with a good margin.
An efficient and balanced straight-through distillation should have a ratio of extraction rate to heating power and water consumption for cooling 1 liter / hour - 0.5 kW - 10 liters / hour. If the power is higher, there will be large heat losses, if it is small, the useful heating power will decrease. If the water flow is higher, the direct flow is inefficiently designed.
The distillation column can be used as a wash column. The equipment for the beer columns has its own characteristics, but the second distillation differs mainly in technology. For the first distillation, there are more features and individual nodes may not be applicable, but this is a topic for a separate discussion.
Based on real household needs and the existing range of pipes, we will calculate typical options for a distillation column using the above method.
P.S. We express our gratitude for the systematization of the material and assistance in preparing the article to the user of our forum.
The distillation column is a complex technical device. It is more difficult to make it than a conventional moonshine still. But it can be done at home. And although distillation columns are freely sold, not everyone has the opportunity to purchase them. In addition, houses, especially in rural areas, are full of improvised materials from which you can make a workable structure and enjoy your own drink. An independent design will cost about 2-3 times cheaper than a purchased mini-distillery.
Components of the structure
A home-made device has the same functional parts as its factory counterpart. The column design consists of the following elements:
- Frame.
- Dephlegmator (refrigerator).
- Nozzles.
- Thermal insulating material.
- Electronic assistants.
The moonshine still as a whole additionally contains:
- Coil.
With proper self-production of a distillation column, it is 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 a tank of optimal volume makes it easier to set the optimum temperature. This parameter during rectification is the main one for the production of a quality product. In addition, preparing for pasture 2-3 liters of moonshine will take the same time as 8-10 liters. Why use time inefficiently when you can get more out of it? In addition, this reduces the cost of the product.
How the column works
Braga is poured into a cube, which is heated. As a result, vapor with an alcohol content 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 on the way it gets on special elements. Braga at the same time continues to boil, and its vapors go up, where they mix with condensate. This continuous process is called rectification. No worse than a home-made moonshine still: 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 up. Its boiling point is below water. From the top of the column, alcohol vapors are discharged to a reflux condenser for purification and saturation, and then to a refrigerator. The result is pure moonshine.
Features of the distillation cube
A container is suitable for a distillation cube, which will answer 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 capacity is required.
Cube heating:
- Electricity.
- Gas.
Many will decide to install the cube on cooker, 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, I installed a heating element in a cube, and took the voltage regulator from an old TV. The Chatelier principle works in the work - 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! The presence of a smooth adjustment of the heating power of the mash will greatly facilitate life. Otherwise, it will be impossible to achieve stable operation from the device.
Application automatic systems control is not essential. To do this, it is better to increase the experience of moonshine. Therefore, at first, a simple mash heating power regulator is sufficient.
But over time you can automate the process. In addition, many people are sorely lacking time. And the automation system in this case is a good help. The process of brewing moonshine will go with minimal human intervention. A ready-made technical solution that will prevent tailings from entering the product can be purchased at a specialized store. The task of such a system is to block the extraction of rectified product at the moment when the temperature in the column ceases to be optimal.
Device and construction assembly
Question self-manufacturing distillation column is considered half. Now you need to take on the main components of the design.
The tsarga of the rectification system consists of:
- A pipe that has a heater and a nozzle.
- Dephlegmator. Includes product take-off unit, cooling jacket and temperature sensor.
- Fitting for external communication.
Alcohol is a volatile substance that is highly flammable. At the top of the column is a hole for communication with the atmosphere. You can't leave it open. It is required to insert a tube into it, and put a rubber tube on it. You can also use a harness.
The end of the tube should be lowered into a container of water. The presence of bubbles will indicate if the alcohol vapor is escaping outside the device. With excessive pressure, and it occurs due to overheating, this will help to avoid an accident.
Column tube
This is directly the nozzle for the column. Here there is a process of interaction of cold phlegm and hot steam. To increase the contact area of these substances, a filler is used. The most common filler is metal washcloths 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 protective layer from stainless steel. The internal structure must be exposed.
Pipe size:
- The minimum diameter is 32 mm.
- The length of the treb affects the quality of the fractionation. The longer, the better the separation.
- The optimal height is 40-60 diameters.
- The minimum height is at least 20 diameters.
Outside, the pipe is wrapped with a thermally insulating layer.
In order for the filler to be securely fixed inside the pipe, a stainless steel mesh should be placed on it from below and from above. The pipe should have a thread for fixing from below to the distillation cube, and from above - for attaching to the dephlegmator.
Ideally, the height should be 1.5 m. This will allow you to get pure alcohol. Standard version - 2 sides 80 cm.
I fill the apparatus with washcloths, and fix them with a tea strainer. In this case, the pressure does not jump. Output speed - up to 1 l per hour. The distillation is not as difficult as it seems.
Dephlegmator
Light fractions condense in the dephlegmator. Device designs may vary. In practice, the straight-through dephlegmator is the simplest. It is also called a shirt or refrigerator condenser. Drawings of a reflux condenser are presented on the Internet, but it is easier to make an option, which is described below.
The design is made of two pipes that have different diameters and are inserted one into the other. A cooling jacket is installed between them.
Components:
- Fittings for a supply and removal of water of cooling.
- At the top is a tube for communication with the atmosphere.
- At the bottom of the fitting for the selection of the product.
Note! To ensure product quality is not compromised, use only silicone tubing and gaskets as the sampling port and seal.
The material for the manufacture of a reflux condenser can be an old thermos or ordinary stainless pipes. The inner tube is equal in diameter to the packing tube. There is no welding at hand - use a soldering iron.
Note! Experts recommend using copper or titanium for moonshine. 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 at home without welding with it.
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 holes:
- For sampling tube.
- For the thermometer when using it.
For experienced 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 dephlegmator and the drawer. Then the indicators should be in the region of 77-81 degrees.
Before the end of the pasture, the temperature usually jumps.
For effective cooling, a screw spiral should be used. Then running water will better go around the dephlegmator.
Refrigerator selection
Note! The use of the Dimroth refrigerator is impractical. The design is different in that substances with a low boiling point can slip through the cooling zone. A dimrot 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 inefficient. So it would be if a dry steamer is attached to the distillation column. But in this type of apparatus it is not needed.
The laboratory glass cooler is an ideal alternative. It can be purchased at any laboratory glassware store. To regulate the rate of product withdrawal, 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.
- Dephlegmator top.
- Dephlegmator.
- Dephlegmator bottom.
- Stock.
Cooling running water will move along this route. It is important that it gets into the dephlegmator shirt warm.
The ideal design of a moonshine still with a separation of fusel oils is distillation column. Subject to temperature regime in it you can get the purest product. But it will be devoid of a peculiar taste.
But in a conventional moonshine still - a distiller - you can get moonshine with a pronounced bouquet. For this, a dryer is used in the design. But there is a nuance - with a bouquet of aromas, moonshine-distillate may contain impurities of fusel oils.
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