Due to the special structure of the distillation column, it becomes possible to almost completely purify the final drink from fusel oils and impurities. Unlike distillation, the quality of the raw material itself does not play such a key role, since there is practically no organoleptic in the final drink. The result is alcohol with a strength of up to 96.6% with a poor organoleptic, but pure. It can be used for the production of vodka and various tinctures.
Consider the principle of distillation column device, and what parts it consists of.
Distillation column, drawing
Distillation column, principle of operation
Rectification is the separation of binary or multicomponent mixtures due to countercurrent mass and heat exchange between vapor and liquid. Parts of the distillation column provide a consistent process:
- Evaporation cube - storage and heating of the bottom liquid
- Column - heat and mass transfer inside the column itself due to packing
- Dephlegmator - vapor condensation, phlegm formation
- Selection node - selection of reflux and rectificate
Consider the work of each part separately.
Evaporation Cube
This is a container in which mash or distillate is stored and heated. It is also called bottom liquid. When heated, the liquid evaporates, and the vapor rises up the column, where it is separated into fractions. At the same time, the cube serves as the base for the column. The cube can be heated on a regular or. On induction - faster and safer.
Also used as a heat source in some models.
Usually, the mash is first distilled to get raw alcohol. The column must be switched to the distiller mode, that is, the selection tap should be opened as much as possible. After that, the raw alcohol is distilled again, this time slowly and with the selection of the food fraction.
A thermometer is located on the cube to control the temperature of the bottom liquid. Upon reaching 60-70 ° C in the cube, it is necessary to supply coolant so that the vapors can condense. Upon reaching 70°C, the power of the heating element must be reduced and left at this value until the rectification is completed.
Tsarga
The tsarga is the body of the column, its central part. Heat and mass transfer, which is the principle of operation of the distillation column, takes place here. It is she who makes the rectification process possible:
- The liquid in the cube evaporates, and the vapor rises up the column
- At the top is a reflux condenser (refrigerator), in which the steam condenses
- The distillate flows down the reflux condenser and along the walls of the column
- The liquid is in contact with the vapor on the walls of the packing with which the column is filled.
- As a result of heat and mass transfer, the most light-boiling fraction accumulates in the upper part of the column
- The low-boiling fraction is condensed in the refrigerator and enters the selection channel.
The column can be assembled from several kings. The higher the column, the more intense the heat and mass transfer takes place, and the cleaner the liquid is divided into fractions. Inside the column is filled with packing: SPN or RPN. Without a nozzle, heat and mass transfer is impossible.
To speed up the rectification process, you can use. The walls of the column are heated, so the phlegm, which is not in contact with the packing, evaporates from the walls. As a result, the process is accelerated, and the degree of purification is increased.
Additionally, they can be used with a column. Heat-mass-exchange between hot vapor and cold phlegm also takes place on its surface. The degree of purification is increasing.
Distillation nozzle
The distillation nozzle is a universal tool that consists of a sampling unit and a refrigerator. In the refrigerator, alcohol vapor condenses, which returns down in the form of phlegm. The selection node allows you to control the amount of alcohol that comes out of the column. By controlling this volume, you can change the quality of alcohol, that is, the degree of its purification. The slower the process, the purer the alcohol.
The nozzle can be bought ready-made or separately.
Alcohol selection unit
Used to improve the quality of cleaning
Automation for distillation column
Rectification requires constant monitoring so that the head and tail fractions do not get into the food part. This process can be facilitated by using the BUR - rectification control unit. The block will limit the selection of rectified product in accordance with the given program so that the tail part does not mix with the food. So you can move away from the column without fear that the tails will fall into clean rectificate.
BUR is an optional part of the distillation column, but it is much more convenient to work with it.
What's next
The resulting alcohol-rectified will have a harsh taste. Alcohol must be diluted, filtered and allowed to brew. You can use alcohol to clean it, it's called. As a result of carbonization, alcohol acquires a milder taste, coal binds the remains of fusel oils, which in a small amount penetrate into the drink even during fractional selection in a distillation column. This is how classic Russian vodka is prepared.
After sorting (dilution) and carbonization, alcohol should rest in a glass container for several days.
Read more about the device and operation of the distillation column in the corresponding product card.
Fire safety of rectification process
Rectification- This is a method of separating a mixture into pure components, carried out by repeatedly alternating the processes of evaporation of the liquid phase and condensation of vapors.
The physical essence of the process consists in bilateral mass and heat transfer between nonequilibrium vapor and liquid flows at high turbulence of the surface of the contacting phases. As a result of mass transfer, the vapor is enriched with low-boiling components, and the liquid is enriched with high-boiling components. With a certain number of contacts, it is possible to obtain vapors consisting mainly of low-boiling components and a liquid consisting mainly of high-boiling components.
The rectification process can be carried out, in the simplest case, in a multi-stage installation. In the first stage of such an installation, the initial mixture is evaporated. The liquid remaining after the separation of the vapors of the first stage enters the second stage for evaporation. In the third stage, the liquid that comes from the second stage evaporates (after being removed from the last vapor). Similarly, the process of multiple condensation can be organized, in which each next stage receives for condensation the vapor remaining after separation of the liquid (condensate) from them in the previous stage.
When enough large numbers steps in this way, it is possible to obtain a liquid or vapor phase with a sufficiently high concentration of the component with which it is enriched. However, the yield of this phase will be quite small in relation to its amount in the initial mixture. In addition, such installations are bulky and their operation is accompanied by large heat losses to the environment.
A much more economical, complete and clear separation of mixtures into components is achieved by carrying out rectification processes in more compact devices - distillation columns.
The work of distillation columns is based on the creation of two counter flows - rising vapors and liquids flowing towards them. The contact between them takes place on horizontal plates, and the vapor approaching the plates has a slightly higher temperature than the liquid in them. The internal volume of the column is conditionally divided into three parts- evaporative, strengthening, exhaustive. In the first volume, the supplied liquid evaporates. The feed is made to the middle part of the column, since in this part the reflux composition is approximately equal to the composition of the solution to be rectified. The heated mixture enters the feed plate of the column and partially evaporates. The vapor phase moves upward, while the unevaporated phase mixes with the phlegm and flows down. The part of the column located above the input of the initial mixture is called strengthening, since the vapor phase in it is strengthened by light fractions. The part of the column located below the input of the initial mixture is called exhaustive, since the remaining light fractions are distilled (exhausted) from the phlegm flowing down in it.
To ensure the normal operation of the distillation column, a constant presence of an upward steam flow and a downward reflux flow is necessary. A heating system is provided at the bottom of the column to produce steam. The rectification process can be carried out at atmospheric pressure, under vacuum, under excess pressure at low temperature. Basically, the rectification process is carried out at a pressure close to atmospheric. Vacuum rectification is applied to mixtures of substances prone to thermal decomposition or polymerization at high temperatures. Low-temperature distillation is used to separate solutions that have a low boiling point.
Consider operating principle of a distillation column, included in the distillation unit continuous action designed to separate binary mixtures.
The distillation column is a vertical cylindrical apparatus with a welded or prefabricated body 1 . The initial mixture is preheated in the heater 5 and fed into the middle part of the column. In the lower part of the column, the liquid is heated to the boiling point. The resulting vapors rise up the column and create upstream. In the upper part of the column, the vapors are taken and enter the dephlegmator 3, where they are partially condensed. A mixture of phlegm (liquid obtained as a result of partial condensation of steam) and uncondensed steam from the reflux condenser is fed into separator 4 for separation. The steam from the separator enters the condenser-refrigerator 6 for complete condensation and the distillate (rectified product) is cooled there, and the phlegm is sent back to the column and creates in it downstream.
Thus, two opposite flows are created in the distillation column - the flow of rising vapors and the flow of liquid flowing down towards them. Contact between them takes place on special heat and mass transfer devices, located along the height of the column with a certain step. Such devices are made in the form of horizontal plates or nozzles.
Essence of heat exchange processes. In the cap column, each plate has several holes with low branch pipes 3, designed to pass vapors rising from below. There is always a layer of reflux on the plates of the column. A cap 2 is mounted on top of each steam pipe, the lower edges of which are immersed in liquid. The caps at the base have serrated slots for crushing the steam into small streams. This increases the area of contact between vapor and liquid. Since phlegm is somewhat colder than vapors, the latter, bubbling through a layer of liquid, cool and partially condense. In the process of vapor condensation, a certain amount of heat is released. In addition, the bottom of each tray is heated by the steam from the underlying tray. Due to this heat, the phlegm heats up and boils. The level of reflux on each plate is maintained by means of overflow pipes 4, which connect all the plates.
In this way, on the plates, phlegm is enriched with a high-boiling component (due to partial condensation of vapors). And the ascending steam flows are enriched with a low-boiling component. Since the vapors are increasingly enriched in the low-boiling component as they move from bottom to top, the boiling point of the liquid on the plates (from bottom to top) becomes lower and lower. At the same time, the phlegm flowing from plate to plate is increasingly enriched with a high-boiling component, and therefore the boiling point is maximum on the lower plates. As a result of the repeated heat exchange process, the vapor removed from the top of the column is an almost pure low-boiling component, and the residue at the bottom of the column is a pure high-boiling component.
From the above, it follows that for the normal operation of any distillation column, it is necessary: so that the initial product was preheated, the upper part of the column was continuously refluxed and the lower part was heated.
It should be noted that in industry, not binary, but multicomponent mixtures are most often separated. In this case, to separate mixtures into three or more fractions, several sequentially operating simple columns or special complex columns consisting of several simple ones are used.
In the ideal case, on each plate of the column, the vapor phase and phlegm are in a state of phase equilibrium and, therefore, each plate corresponds to one of the points lying on the equilibrium curve (considered at the beginning of the lecture). In reality, the complete equilibrium of the phases on the plates of the distillation column is not achieved. This is taken into account by introducing an efficiency factor.
To approach the phase equilibrium of the actual concentrations of liquid and vapor developed various designs plates and bowls. Trays or packings are the most important structural element of distillation columns. It is on them that the process of heat and mass transfer occurs between the ascending steam flow and phlegm.
Distillation columns in which heat and mass transfer devices are made in the form of plates are called bubbling , as steam is bubbled through the reflux layer. If heat and mass transfer devices are made in the form of various nozzles, then the columns are called packed .
bubbling distillation columns may have trays with or without downcomers. Plates with drain devices. These include cap, sieve and valve.
Used to separate solutions capped plates. This is due to the fact that this type provides good contact between the steam and phlegm on the plates. The mixture of vapors, rising, passes through the nozzles (Fig. 3, methodical material) and, hitting the caps, bubbles through the layer of phlegm on the plates. The caps have holes or serrated slots for crushing the steam into small jets. The inflow and outflow of liquid is regulated by means of overflow tubes.
Sieve plates, have a large number of small (from 0.8 to 3 mm) holes. Steam passes through the holes of the plate and is distributed in the liquid in the form of small streams and bubbles. An important requirement is constant speed steam movement and its pressure sufficient to overcome the pressure of the liquid layer on the plate and prevent it from flowing through the holes.
Sieve plates are distinguished by simplicity of device, ease of installation, inspection and repair. But they are sensitive to the presence of impurities that clog the holes of the plates and create conditions for the formation of increased pressures. In the event of a significant decrease in vapor pressure, all the liquid from the sieve trays drains down, and in order to resume the process, it is necessary to start the column again. This imposes significant restrictions on the use of this type of plates.
Valve plates. They have openings blocked by special valves that rise depending on the magnitude of the steam pressure. When the valve is lifted, a gap is formed through which the vapor passes bubbling through the liquid layer. With a change in pressure, the valve closes under its own gravity. The valve lift does not exceed 8 mm. The advantage of such trays is a relatively high throughput of steam, high efficiency in a wide range of loads. The disadvantage is the increased hydraulic resistance due to the weight of the valve.
Plates without drain devices. Their feature is that steam and phlegm pass through the same holes or slots. On the plates, simultaneously with the interaction of reflux and steam, by bubbling, a part of the liquid drains to the underlying plate. The liquid "falls through". Allocate perforated plates, lattice, tubular, wavy.
Packed columns. Heat and mass transfer between steam and phlegm proceeds in the volume of nozzles made of solid bodies various shapes(table with nozzle types). The principle of operation of the columns. Steam from the exhausting part moves up the column towards the flowing liquid. Distributing over a large surface of the packed bodies, the vapor intensively contacts the liquid and loses part of the high-boiling component and is enriched in the low-boiling one. The requirements for packings are a large surface per unit volume, good reflux wettability and its uniform distribution throughout the packing, low hydraulic resistance, chemical inertness, and mechanical strength.
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 finished one. 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 sugar mash or distillation waste (“heads” and “tails”) are distilled into alcohol, so the main goal of rectification is to maximize the purification of the output from 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 the chemical composition of the 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 a certain optimal size of the packing, which depends on the diameter of the column and will allow to achieve the best combination 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 cross-sectional area of the column (sq. mm), and therefore are proportional to the square of the diameter. Pay attention to this when choosing a tsarga, always consider inner diameter and compare options.
Dependence of power on pipe diameter
Pipe height. To ensure good holding and separation capacity, regardless of the diameter, the height of the distillation column should be from 1 to 1.5 m. If it is less, there will not be enough space for the fusel oils accumulated during operation, as a result, the fusel oil 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". In other words, with increasing pipe height, the increase in the separating capacity of the distillation column for each additional centimeter 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 used gas, induction or conventional gas to heat the moonshine electric stove, 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 for adjustment use a relay with output voltage stabilization, for example, RM-2 16A. 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 must 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 spray. 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 are building a column with liquid extraction or steam below the reflux condenser, then the required power must not be less than the rated 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 inner tube, then start the selection in the shirt, 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 proceed not from the need of the Republic of Kazakhstan, but from maximum power heating 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. 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 kinematic viscosity coefficient of vapors.
Possible design of a once-through refrigerator In order not to go into unnecessary details, we will give 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 systems cooling, 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 in - 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. Equipment for mash 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 calculate using the above method typical options distillation column.
P.S. We express our gratitude for the systematization of the material and assistance in preparing the article to the user of our forum.
Column for rectification - necessary fixture, which allows you to isolate from the mash not just strong moonshine, but real pure alcohol with a strength of up to 96 degrees. A moonshine still with a distillation column opens up great opportunities for beginners and experienced distillers. What is the difference between a moonshine still and a distillation column? Is it mandatory in the manufacture, and what advantages does it provide? Let's figure it out.
Distillation column
What is a distillation column?
A column is a component of a distillation circuit, consisting of a metal (stainless steel, copper) or glass flask, as well as a filler and special fasteners-adapters (most often, a clamp connection is used, which allows you to quickly install and remove the device).
Distillation column, scheme As a filling that increases the usable area of the inside of the distillation column, various options are used:
- glass or ceramic balls;
- regular wire nozzle (RPN);
- SPN (Selivanenko spiral wire nozzle), etc.
The principle of operation of a distillation column in a moonshine still is based on an increase in the contact area of substances evaporating from the mash - alcohol vapors, heavy and ultra-light fractions.
Unlike simple distillation, during rectification using a column, the vapors released from the mash during heating are separated into components. The resulting product is pure, without impurities in the form of heavy fractions, alcohol. Foreign substances settle back into the distillation cube, flowing down the walls of the column, and more volatile alcohol vapors pass into the condenser (tubular-type refrigerator or with a coil). Additionally, distillation equipment is equipped special devices- a reflux condenser, a drop eliminator, a dry steamer, etc. Each of them serves to improve the quality of the resulting product.
The best moonshine stills and distillation columns allow you to get alcohol, moonshine and spirits of excellent quality at home.
The principle of operation of the distillation column Which is better - a simple apparatus or a distillation column?
In fact, posing the question in this way is not the most correct approach. serves to obtain a sufficiently strong raw alcohol, the strength of which usually does not exceed 70 degrees. With competent distillation with cutting off the "heads" and "tails", the output is a strong alcoholic drink with a rich flavor composition, which includes notes characteristic of the original raw material. Moonshine made from honey, fruits, berries, grains is especially popular - their characteristic tastes delight lovers.
The distillation column allows you to get the finished product - rectified alcohol The product obtained on a simple moonshine requires additional operations - cleaning, filtration, double fractional distillation.
The columns are used to obtain purified alcohol with a high strength, but without the tastes and aromas of the feedstock. They do not need additional cleaning and, as a neutral alcohol base, are suitable for making vodka, tinctures, liqueurs. The distillation column allows you not to distill the mash twice, getting the finished product right away - rectified alcohol, suitable for both technical needs and food purposes. When distilling through a column, dry steamers and gin baskets are used to improve the flavoring properties. Aromatic raw materials are placed in them, which gives essential oils when passing through herbs, dried fruits, spices, alcohol vapors. A moonshine still with a distillation column and a steamer is perfect for making gins, flavored vodkas, tequila.
Sukhoparnik with a gin basket Pros and cons of using a distillation column in a complete set of distillation equipment
It should be noted right away that conventional distillation equipment is more affordable - it is cheaper and easier to handle. But its functionality is less wide. Among the advantages of the column:
- the ability to obtain pure alcohol - rectified;
- distillation mode for obtaining moonshine of a high degree of purification;
- the absence in the final product of foreign harmful impurities and substances that worsen the taste of drinks.
The device also has disadvantages - the columns have a lower capacity, when obtaining a rectified product, it is necessary to pour diluted raw alcohol into the distillation cube. This implies the primary distillation in a moonshine still.
Many experienced distillers believe that the column is needed only to obtain alcohol from raw materials that do not have special valuable taste properties - sugar mash, old jam, etc. Otherwise, it is better to use a conventional apparatus.
Sieve Distillation Column You can also use a special sieve column. It, depending on the number of installed plates (discs), allows you to get both moonshine of a high degree of purification, and drinks with the preservation of the original flavor composition of the raw material.
The device is installed on universal distillation apparatuses with provided connections for mounting various additional devices.
Nozzles for columns and their varieties
Truly enthusiastic distillers are willing to experiment with nozzles for filling distillation columns. They use both factory models and all kinds of homemade products. Among the first, three options can be distinguished.
- Wire regular nozzles made of metal mesh. The material is copper or stainless steel. Due to the large area, heavy fractions are retained, flowing back into the distillation cube, and the volatile vapors of pure alcohol rise higher - into the condensing device (refrigerator - tubular or spiral) and are fed to the outlet in the form of a liquid.
Regular wire packing for distillation or beer column - Bulk spiral nozzles. They consist of many tiny spirals. The material is also metal - stainless steel or copper. The latter is used to eliminate sulfur compounds that greatly spoil the organoleptic characteristics of the final product.
Bulk spiral packing for distillation column - Special ceramic or glass balls. They also serve to increase the working area of the column and to retain heavy fractions.
Distillation column “Dobrovar Ermak” Homemade nozzles sometimes have no worse working qualities. Amateurs make them from wire, twisting it into a spiral and cutting it into small pieces, use various materials often combining them.
Some distillers with extensive experience believe that a do-it-yourself distillation column for moonshine is the best option. But in order to get a truly effective device, you need to have the necessary knowledge and skills, understand the principles of the device. Therefore, for beginners, there is only one way out - to purchase a column in a specialized store. But, if you wish, you can find a diagram of a distillation column for a moonshine still on any forum dedicated to moonshine.
Common Questions
Newcomers to the production of alcohol and homemade drinks from it often have various questions. Here are the answers to the most common ones.
Is it possible to get a rectificate in one distillation from mash?
No. Direct distillation through a mash column can lead to clogging of the flask and nozzle due to foam rising. It is necessary to overtake the mash, having obtained raw alcohol, dilute it to 15-20 degrees and overtake using a distillation column at a low temperature.
Do you need a column to get high-purity moonshine?
A distillation column for a moonshine still is not necessary to obtain such a product, although it is easier to do this with it. To obtain a quality product, fractional double distillation can be used in a conventional apparatus.
Is it possible to get alcohol with a strength of 96 degrees on a conventional moonshine still?
The maximum strength obtained on distillation equipment is 70-80 degrees. To obtain rectified (96 degrees) requires a distillation column.
Does a copper regular packing in a column replace alambicas, caps and coils made of that metal?
Yes, sulfur compounds are removed with a copper mesh or spiral filling just as efficiently, and the cost of nozzles is much less than copper distillation equipment.
The conclusions from the information presented are simple - distillation columns are designed to produce high-quality alcohol from not very valuable raw materials. Distillation of mash from fruits, grains, berries will require a more subtle approach and familiar distillation equipment. On the other hand, a distillation column is more suitable for beginners. With its help, it is easier to get alcohol without harmful and dangerous impurities. As a compromise, you can use a professional moonshine with a distillation column, other useful devices, as well as the possibility of modernization.
To get pure moonshine, home cooks usually resort to double distillation. The result is a quality product without harmful impurities, with a pleasant taste and aroma.
An even better effect is obtained by distillation in a distillation column. It allows you to get the most purified strong alcohol (94-96%) or vodka without additional flavors and odors.
At the same time, the device has practically no disadvantages, with the exception of large dimensions and the need to work hard on its manufacture. Most experienced moonshiners agree that it is better to assemble the distillation column on their own.
The design and principle of operation of the 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 tsarga, reach the refrigerator and the selection unit, the valve of which is closed at the initial stage.
Condensed vapors (phlegm) descend 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 interact continuously.
This process of exchange is the rectification process. The lightest vapors with a high alcohol content are discharged to the refrigerator, where the final condensation takes place. As a result, pure distillate enters the receiving tank.
Calculation of parameters and selection of materials
Before proceeding with the assembly of the column, it is necessary to determine the dimensions and other characteristics of the apparatus.
Drawer height
If earlier 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 the dimensions is as follows: the height of the pipe should be approximately 50 times its diameter. Small deviations in one direction or another are allowed. However, the length of the tsarga cannot be less than 1 meter. Otherwise, part of the fusel oils will fall into the selection, and there will be difficulties with the separation of fractions. An increase in the height of the column over 1.5 meters does not significantly affect the quality of the product, but lengthens the distillation time. In addition, it will be problematic to place such a design at home. Optimal dimensions pipes: length - 1.3-1.4 m, diameter - 3-5 cm.
Material and wall thickness
The ideal option for the tsarga is food grade stainless steel: it does not affect the composition of drinks in any way. Copper will also work. The optimal wall thickness is in the range of 1–2 mm. More is possible, but this will make the structure heavier and increase costs without bringing much benefit. In addition, it is worth remembering that holes will have to be made in the walls.
Type and parameters of nozzles
As a contact element, it is easiest to use household stainless steel washcloths, 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 for a day: a good product will not rust. Alternative options are glass beads, stones of certain breeds, metal shavings. The packing density is 250–270 g of the contact element per 1 liter of the column volume.
Cube volume
The distillation vessel is filled 2/3, while the amount of alcohol-containing liquid should correspond to 10–20 nozzle volumes. For a column with a diameter of 5 cm, it is optimal to use a tank of 40-80 liters, for a width of 4 cm - 30-50 liters.
Heating source
It is not recommended to use gas, electric or induction cooker. The first option is dangerous, the rest do not allow for a uniform supply of heat. The best option is electric heating with the help of heating elements, which can be built into the cube yourself. The power of the elements depends on the volume of the cube: at least 4 kW is required for 50 liters, at least 3 kW for 40 liters, etc.
Type of thermal insulation material
It must withstand high temperatures, be chemically inert. Usually they use foam rubber 3-5 mm thick, fluoroplastic or silicone (but not rubber!) Gaskets.
Docking option
If used threaded connections sealant may be required. It is better to give preference to putting the elements on top of each other.
When creating a distillation column, every little thing matters, so all recommendations should be strictly followed. It will not be superfluous to watch the video of the assembly.
In one part, which will be at the bottom, the selected type of nozzles is poured, having previously installed a grid and a thrust washer to prevent material from falling out. If metal sponges are used (about 40 pieces are required), pre-cut them into pieces of 5 mm. The springs should be distributed evenly by tapping the pipe on a hard surface. After filling the nozzle, close the pipe with a mesh, fix it with a washer.
Connect the resulting structure to alembic and insulate it with thermal insulation material.
The second (upper) part of the pipe is connected to a dephlegmator using a soldering iron. The water housing should have 2 branch pipes: for water inlet and outlet. A reflux condenser can be bought or made independently from a thermos, pressure cooker, coil, copper tube (the first options are preferable). For example, like this: https://youtu.be/D4ZsbbRH6ds
The upper end of the column is closed with a stopper/lid or sealed, leaving a hole for installing an atmospheric tube. To secure it, a fitting is used, the end of the tube is lowered into the water.
Make a hole for the pipe to exit the distillate. It should be a couple of centimeters above the junction with the bottom of the pipe, a plate is installed under it to collect condensate.
By using silicone hose connect a refrigerator to the column. You can buy it or make it yourself. To regulate the process of fluid movement, a dropper clamp 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 sewerage. Thus, the water to the dephlegmator will be heated.
Additionally, you can install a water flow regulator and a thermometer (it will require an additional hole in the selection unit).
You can also divide the drawer into 3 parts: this design is considered more variable in application. Detailed Process the assembly of the column can be seen here:
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