To obtain pure moonshine, home cooks usually resort to double distillation. The result is a high-quality product without harmful impurities, with a pleasant taste and aroma.
An even better effect is achieved by distillation in 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 initially 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 easiest pairs with high content alcohol is taken 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 part fusel oils will be included in the selection, and difficulties will arise with the division of factions. 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. The optimal wall thickness is in the range of 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: a good product will not rust. Alternative options are glass beads, stones certain breeds, 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
It is not recommended to use gas, electric or induction cooker. 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 threaded connections are used, 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, a pressure cooker, a coil, or a 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 the bottom of the pipe; a plate is installed under it to collect condensate.
Using a silicone hose, connect the 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: the upper part of the refrigerator with the bottom of the reflux condenser, the upper part of the reflux condenser with the 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:
This article brings to your attention a version of a distillation column assembled from available materials, with reflux condenser made from an ordinary household thermos. A thermos with a volume of 0.5 or 0.75 liters is an almost ready-made dephlegmator, which significantly simplifies the design and reduces the amount of work. The productivity of the column for rectified alcohol is 1-1.5 l/hour, depending on the diameter of the pipe. Some column elements will require turning work to produce them. As an evaporation container (distillation cube, hereinafter simply a cube), for raw alcohol (moonshine), you can use any suitable size, starting from two liters, the upper limit is not limited. The cube can be heated in any way, but for safety reasons, you should try, if possible, not to use an open fire for heating.
To make a column you will need:
Tools and equipment you will need:
During the operation of the column, to control the temperature regime and monitor the order of fractions exiting, you will need:
thermometer up to 100 g
You can use a mercury thermometer with a division value of 0.5 g, or in extreme cases 1 g. Or better yet, with an accuracy of 0.1 g. Inexpensive can be used multimeter with thermometer function.
You will also need it to measure the pressure drop in the cube, although you can do without it.
To supply and discharge coolant, you will need a flexible hose or hose with a diameter of 5-6 mm.
To select the resulting distillate, a diameter of 5-6 mm will be required.
And so, if you want to independently make a column to obtain pure 96% alcohol, then go ahead to the store to purchase the above materials and the missing tools.
To do this, first of all, we’ll take the pipe to a turner so that he can cut off the centimeters we don’t need from the pipe, carefully remove the chamfers and thus trim off the edges of the pipe. If you don’t have a turner, it doesn’t matter, we cut it evenly with a metal hacksaw, as much as necessary, trying to maintain the cutting plane at an angle of 90 degrees to the body of the pipe. To do this, you can evenly wrap the pipe at the cut site with electrical tape and cut along its edge. Then, using a flat file, we align the edges of the cut and remove the burrs. Use a round file to process the inside of the cut. Then we polish it with sandpaper to prepare the surface for further soldering. Next, we will need to make an adapter to connect the pipe to the lid of the cube, as well as a distillate selection unit. If there is a turner, then we order these parts from him. The adapters should be tightly inserted at one end from the inside or put on from the outside of the pipe. This will depend on the diameter of the pipe itself and the ability to machine or obtain an adapter for this diameter. On the other hand, the adapter must have carving . The thread can be metric, inch or pipe. It is preferable to make the thread pitch no less than 1.5 and no more than 2. If you don’t have a turner, you’ll have to buy an adapter at a plumbing store. 1" or 1¼" adapters will fit depending on the pipe diameter. It is better to take the adapter not nickel-plated, but brass, so that it can be lighter and then tinned. But with the selection unit it is more difficult; you will have to improvise on the go, depending on the available parts and the configuration of the neck of the thermos. You can select suitable parts from a plumbing store and, by fitting them together and then soldering them, assemble a selection unit. Then you need to make support washers for nozzle. The diameter of the washer should be such that it ensures a tight fit of the washer into the pipe. The holes in the washer should be drilled as often as possible and have a diameter of at least 3 and no more than 4 mm. Insert a washer into the pipe on one side to the desired depth. Next, you need to solder an adapter to the pipe to connect it to the lid of the cube. To do this you need a soldering iron, solder (preferably pure tin, it does not contain lead) and soldering acid. First, we clean the intended soldering areas on the pipe and adapter with sandpaper or a file. Then we apply soldering acid and heat it with a soldering iron with a drop of tin. Additionally, you can warm up the soldering area gas burner. As it warms up, the tin will begin to melt and spread. Thus, you need to tin the entire surface of the adapter to be soldered, as well as the surface that will come into contact with alcohol (but this is only if the adapter is not made of stainless steel). There is no need to tin the stainless steel adapter. Remove excess tin deposits while hot using a rag from natural material(not synthetics). Then insert the tinned adapter into a pipe tinned in the same way and heat the soldering area with a soldering iron, or better yet, with a gas burner. The tin will melt and securely fix the parts together. Then we start making column nozzles . Next, pour the nozzle into the pipe, periodically shaking the pipe slightly to ensure even placement of the nozzle. No need to shake too hard. Thus, we fill the pipe to the very top. We insert another support washer for the nozzle into the pipe. Then we insert the tinned end of the extraction unit and heat the soldering area (naturally, the second end of the pipe is also tinned). We put a heat insulator of the required diameter on the pipe and at this point we can consider the manufacture of the distillation part of the column complete.
To do this, you need to clean the bottom of the thermos with sandpaper.
Make something like a bracket out of a strip of tin.
Then from steel wire make a kind of loop, insert it into the hole in the bracket and twist it with pliers.
Clamp the other end of the wire in a vice or nail it to the wall. Take the thermos with both hands, move it away from you and pull it hard. The lid (bottom) should come off. It should be mentioned that some of the bottoms are set loosely and fly off quite easily, and some require very great effort and sometimes the bracket at the soldering site comes off, but the bottom remains in place. In this case, you need to increase the contact area between the bottom and the surface bracket, solder these parts again and try again.
It is necessary to grind around the perimeter of the welding seam connecting the lid and the flask. It is better to do this on an emery machine.
But you can also use a drill attachment. You need to grind as evenly as possible and watch for the appearance of a small, barely visible gap between the lid and the flask.
You need to grind until a gap appears around the entire circumference.
After this, the lid is easily removed from the flask. Another flask will be visible under the lid.
If necessary, you can also remove it by sanding the weld seam around the perimeter.
After which the inner flask is easily removed from the outer one.
As a result of all the manipulations to disassemble the thermos, we have two separate flasks.
But if no modifications are provided for in the design of the thermos, then you should not remove the inner flask from the outer one. To make a reflux condenser, it is enough to remove the bottom and vacuum cover and gain access to the inner flask. Next, in the inner flask, in the center, on the back side, you need to drill a hole for a tube for communication with the atmosphere. Clean and then tin the soldering area, both the flask and the tube. Then insert the tube into the hole and solder it securely. The hole must be of such a diameter that the tube can be inserted into it with tension. This will make soldering easier. When soldering, try not to allow solder to flow onto inner side flasks. Then also drill a hole in the center of the bottom and tin the soldering area, tin the mating surfaces of the flask and the bottom. Place the bottom on the flask and solder it. Then solder the tube and bottom. Then tin the neck of the thermos and the selection unit. Insert the selection unit into the neck and solder it by heating with a soldering iron or gas torch. Carefully, without damaging the inner flask, drill holes in the outer flask at the bottom and top for the cooling water inlet and outlet pipes. Tin, insert tubes and solder. In the distillate sampling unit, drill a hole for the thermometer sleeve. It is advisable to make the sleeve from fluoroplastic. Drill a hole in the bushing to the diameter of the thermometer probe. Insert the bushing into the take-off unit. You also need to drill another hole in the selection unit to select the distillate. Insert the tube and solder. At this point, the manufacture of the reflux condenser can be considered complete. Next, you need to thoroughly rinse all soldering areas with a solution baking soda in the water. Then screw the reflux condenser to the column and rinse the entire assembly under running water.
Before using the column for the first time, you should carefully study rectification theory. Then you need to run the column for as long as possible (several hours) without sampling the distillate in order to wash the contaminants remaining after washing with water from the surface of the nozzle, pipe and reflux condenser. After this you can begin to select head fractions into a separate container. These fractions will wash the refrigerator and distillate selection tubes from contaminants. And only after this we begin to select the main one - food fraction . If you don’t understand something from the description, ask questions in reviews and comments. I will try to answer them soon.
A variant of a reflux condenser with a removable large-diameter lid made of a stainless steel cup
There is also no welding in this option. The bottom needs to be done big hole. The hole should be of such a diameter that a small flask would be difficult to push into it, that is, with as little clearance as possible. I did this with a special drill that I made myself some time ago. Nowadays they are sold for cutting round holes in ceramic tiles. There is a drill in the center and two more cutters with pobedit tips on the edges; you set these two cutters to the required diameter and drill at low speeds, pouring water on them. It takes 1-2 minutes. The hole is smooth, without burrs or burrs. But it is advisable to drill on a drilling machine; with a drill there is a risk of breaking the cutters or turning the bottom out. If there is neither such a drill nor a machine, then you need to punch it exactly in the center. Take a caliper with a sharp edge and draw a circle of the required diameter, then drill the largest possible drill, then take a cone-shaped drill attachment and bore the hole to the drawn circle, especially at the end you need to be careful so that the hole turns out even. Well, naturally you try it on more often at the end of the boring. This usually takes 15-20 minutes. Next, sand the edges to be tinning until they shine and then tin them. Then you pull the bottom onto the flask with gentle rocking and solder the joint. Further, or rather, this should be done at the very beginning. You also need to drill a large hole in the inner flask. Why is it big, because instead of a lid, a conical stainless steel cup will be inserted there, cut approximately in half; do you know the principle of closing a can of coffee? There is a rather large hole there, but it closes hermetically due to the tension and springy properties of the lid. The same is true here, the cone of the cup fits very tightly into the hole of the flask, and no fluoroplastic or other lids are needed. and through this large hole, firstly, everything is visible what is happening there, and secondly, a hole is drilled in it for a tube that connects to the atmosphere, as well as for a tube into which the thermometer probe is subsequently inserted.
To build such a unit, you need to know the basic principles of the column’s operation and the essence of the processes that occur in it. And a lot of interesting things happen there - the rectification process is distinguished by its physical and chemical bases from conventional distillation.
How does a column work?
As in a conventional distiller, the column has both a heater and a refrigerator, which are full-fledged working elements. But on the path of alcohol-containing steam from the surface of the mash to the refrigerator coil there is another complex unit, which is called a distillation column. It is a tall pipe, the diameter of which is 30-50 times greater than its length. Optimal dimensions for heat and mass transfer processes that occur inside the column.
The heated steam rises up the pipe, slowly cools along the way, condenses, and flows down, back into the container. As it moves from top to bottom, the condensate comes into contact with hot steam, is reheated, and the low-boiling components turn back into steam. Among these components is ethyl alcohol. If you select the operating mode of the column in such a way that alcohol vapor begins to condense at a certain height, where the intake pipe is installed, then pure alcohol, without impurities, will flow into the refrigerator.
After some time, a dynamic equilibrium mode will be established in the column, due to the difference in heat capacities of the liquid and vapor phases; in addition, the liquid-vapor mixture is divided into fractions according to chemical composition, on which the vaporization temperature depends.
In the very top part, vapors of volatile impurities - aldehydes, acetone and other toxic substances - collect. When the temperature at the top thermometer of the column is above 70 C, they simply fly away into the atmosphere - the column is connected to the outside air by a pipe or valve and operates almost at atmospheric pressure.
At a height of approximately ¾ of the length of the column, alcohol vapors accumulate, which need to be collected. Below are fusel oils and other substances whose boiling point is higher than alcohol. In the alcohol selection zone, the temperature should be maintained at 74-78 C. To make this possible, a significant height of the column is required; the larger the zones of different fractions, the easier it is to separate one substance from another.
How to make a rectification column
A homemade distillation column at home is not a myth. This is confirmed by numerous videos and photographs on the Internet and posts on forums. Even if they are half as good as the craftsmen say about them, then such a device is worth making. But we must take into account the fact that for the production of moonshine, as such, a distillation column, regardless of whether it is home-made or industrially made, is unsuitable.
The rectification apparatus is designed to produce alcohol with a minimum of additives, including aromatic substances and resins, which give moonshine a special aroma and taste. But the resulting alcohol can be used as a base for any alcoholic drinks made at home, without fear of poisoning with fusel or methyls and ethers, which contribute to a severe hangover.
For re-distillation of raw alcohol or ordinary moonshine obtained in a distiller familiar to moonshiners, a rectifier is an indispensable thing. No distillation system can compare with the quality of the resulting product.
Column manufacturing technology
A do-it-yourself distillation column will work properly at home only when its height is at least 1.8-2 m with an internal diameter of 40-50 mm. Such a column is difficult to manufacture, store and operate. It is best to make it collapsible, with clamp or threaded connections; it is also convenient to use couplings. If you have the skills to work on lathe, then the coupling connection will not be a problem. Otherwise you will have to use paid services professionals.
What does a column consist of?
The main components of the distillation column:
- frame;
- refrigerator-reflux condenser;
- nozzle (disc or spiral);
- thermal insulation;
- thermometers.
The entire moonshine still also includes a tank for mash and a refrigerator for condensate, which is a regular coil. If you make a distillation column correctly, it can be installed on any moonshine still with a tank with a capacity of at least 20 liters. At smaller volumes, it will only be possible to accelerate it to operating mode and obtain several liters of alcohol (50 percent of the possible yield).
The optimal evaporator volume is 25-50 liters. This makes it more convenient to regulate the process temperature, which is one of the main factors during rectification. In addition, the production of alcohol with a volume of up to 8-10 liters takes the same amount of time to prepare and disperse the column as 3-5 liters. Saving time is also in most cases very important for reducing the cost of the product.
Column body
It is best to make it in three parts, approximately equal in length. At the bottom, a flange is welded to the stainless pipe for installation on a distillation tank with a strong lid. The height of the column is impressive - about 2 meters. A flange connection with a sealed gasket is the optimal solution. The flanges must be welded in such a way that the column is in a strictly vertical position, this is the only way it will work properly.
The body segments are connected with clamps or threads - whichever is more convenient. The main thing is to ensure tightness. The best material for the main pipe of the column is food grade stainless steel. It has relatively low thermal conductivity, and heat loss in the column is undesirable, up to the point of vapor entering the refrigerator.
The two lower parts of the column are simply sections of pipe. They will contain nozzles - special devices that increase the contact area between steam and liquid. The more complex uppermost part is there:
- a flow-through refrigerator must be equipped;
- a drain pipe is provided;
- thermometer socket;
- air valve.
The flow cooler occupies approximately ½ of the top third of the column. The simplest solution is to wind a copper or stainless steel coil over the pipe. A more complex option is to place the same coil, ball cooler or Dimroth cooler inside the pipe. For this purpose, you can use a larger diameter pipe, connecting it to the lower part using an adapter.
There are many options here - the essence is the same, the reflux condenser must provide a barrier to the steam and turn it into condensate before reaching the air valve. Only vapors with a temperature no higher than 60 C should penetrate there. If the refrigerator does not cope with its task, then alcohol will escape into the air along with volatile substances.
The air valve is installed at the highest point of the column and serves to equalize the pressure. You can not install the valve, but simply install a thin copper tube (Ø 3-6 mm). The presence of a tube requires special temperature control at all stages of rectification. When selecting heads, T = 55 - 65 C should be at the level of the intake pipe.
The selection is carried out through a pipe cut into the body below the refrigerator at a distance of 2-5 cm from it. It is a regular tube to which a silicone hose from a medical IV is connected. A do-it-yourself distillation column works very slowly; the main intake is carried out in drip mode. This must be taken into account - the production of 8-10 liters of alcohol takes a whole working day.
Nozzle
This part of the column is one of the most important. For rectification, two types of nozzles are used - disc-shaped, in the form of cap or sieve elements, and spiral, made of metal mesh, tightly twisted into a spiral or special wires twisted into prismatic spirals, which are simply poured inside the column. In the latter case, a mesh filter is installed at the bottom of the column to prevent the nozzle from falling out.
The most effective cap-type disc nozzle for a do-it-yourself distillation column. You can make it yourself from finished parts, sold on the Internet. In this case, the work should begin by purchasing the plates - the diameter of the body must correspond to their size. It is easier to find a pipe for the cymbals than vice versa.
Copper plates for column
Mesh partitions are much easier to make; all you need is a drill or drilling machine and a set of 2-3 mm drills. Partitions are made of stainless steel, brass or copper. There should be 8-10 of them per 1 m of column height.
Mesh, special spiral prismatic attachments Panchenkova (RPN) or analogues will have to be purchased in specialized online stores. You can't do them yourself. You cannot use mesh for washing dishes, as some sites recommend - they use unknown alloys that can react with alcohol vapors or impurities.
Thermal insulation
The column must be protected from heat loss to a height not less than the lower cut of the reflux condenser. Any elastic heat insulator is suitable for insulation - polyurethane foam, Penoizol, basalt tubular foil insulation of the TECHNONICOL type. Insulation - very important stage. If heat loss is excluded, the height of the fractional layers can be reduced by several tens of percent. At the same time, the concentration of the substance, in our case alcohol, in them will increase while maintaining clear fraction boundaries.
A homemade distillation column, with its complexity and low distillation speed, will allow you to obtain alcohol of sufficient purity from proven raw materials. From a properly prepared mash, the product yield, in terms of 40 0 strength, will be 25-30% higher than that of a conventional moonshine still, with incomparably better quality.
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At the next stage you can do heating element the entire apparatus. For this you can use a regular boiler. Having retreated some distance from the end of the wire, so that it is enough to reach the device, you need to cut off a part, you will have to screw everything back afterwards. The ends of the cord from the boiler must be threaded so that when the lid is closed, the element is inside the body. After stripping the wires, they need to be connected back
It is important to take care of high-quality insulation.
The boiler should not touch the bottom; it is advisable that it be completely covered with liquid during operation. Into the same hole through which the boiler cord passes, you need to insert the long end of the coil for the apparatus. The remaining gaps between the tube and the cord must be filled with pieces of cotton wool, making it quite tight. It is important to achieve the best sealing possible.
The resulting structure made of cotton wool must be filled with superglue, which is made on a cyanoacrylic base. This will allow you to obtain the most airtight connection using composite materials. Once the glue has hardened, you will be able to obtain a sealed seal. strong connection. All that remains is to make something like a casing for the fan so that the air washes over the fins of the heat exchanger, represented by a coil.
To make the casing, you can use Tetra-Pak packaging. If you are making a moonshine still, then you can use the technology presented in the article. You need to cut a rectangle from the packaging, the width of which will correspond to the dimensions of the fan. These elements will be used to cover the fan on 3 sides. The end of the coil needs to be brought to the fourth side in order to drain the moonshine. In the remaining side wall you need to make a hole for this part of the tube and glue it with the superglue used earlier. The walls can be glued together with tape. When it is necessary to ensure maximum safety, it should be covered with a transparent protective screen.
On this we can assume that mash column ready. You can use a computer power supply as a power source for the fan. To turn it on without using the motherboard, you need to connect the black wire with the green one. Experts use more compact 12-volt sources, which you can find yourself.
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 heightIf 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 pipe dimensions: 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 in any way affect the composition of the drinks. Copper will also work. The optimal wall thickness is in the range of 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 The easiest way to use household stainless steel sponges as a contact element is to use them 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: a good product will not rust. Alternative options are glass beads, stones of certain types, and metal shavings. The packing density is 250–270 g of contact element per 1 liter of column volume.
- Volume of the 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.
- Heat source: 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.
- Type of thermal insulation material It must withstand high temperatures and be chemically inert. Typically, foam rubber 3–5 mm thick, fluoroplastic or silicone (but not rubber!) gaskets are used.
- Joining optionIf threaded connections are used, sealant may be required. It is better to give preference to putting elements on top of each other.
Design selection
The size and design of the device depends on a number of factors:
- Required performance. with higher productivity, the padded drawer will be higher and wider - the steam passes through more. The cooler and extraction unit must also provide sufficient efficiency. The minimum length of the drawer is 1.5 meters, it is better to make it collapsible from three bends - 1 meter, 0.2 meters, 0.5 meters. this will allow the device to be used for both distillation and rectification.
- Possible sizes. Often home distillation columns are limited in size due to ceiling height. Shifting the dimrot refrigerator in the upper part of the apparatus, or placing it perpendicular to the drawer (Thor's hammer) will help save space.
- Access to metalworking technologies. A stainless steel device will last a long time and will not oxidize alcohol, but to connect the parts you will need argon welding or stainless steel electrodes. Cooking stainless steel is difficult. If possible, you can use laboratory heat-resistant glass, but it is too fragile. Great option for the homemaker - copper. It can be easily soldered with a gas torch and is commercially available large number
- Volume of refilled raw materials. The larger the cube used, the higher the productivity should be. Evaporation of alcohol occurs at 75 - 80 °C; lowering the temperature will reduce the speed of the process.
- Budget. With a minimum budget, you should consider a simple but effective design with mechanical adjustments. If the budget is not tight, the device is supplemented with precision needle taps, additional components and automatic control.
A distillation column 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 homemade moonshine still is no worse: a do-it-yourself distillation column will have the same properties as a factory-made 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
A container suitable for the distillation cube, 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.
Pay attention! Availability smooth adjustment 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.
Pay attention! 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. Internal structure must be naked.
Pipe size:
- Minimum diameter - 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 to the bottom still, and on top - for connection to the reflux condenser.
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.
Pay attention! 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 steel 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.
Pay attention! 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
Pay attention! 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.
Laboratory glass cooler - perfect alternative option. 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.
The ideal design of a moonshine still with fusel oil separation 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 normal moonshine still- 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.
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