Distillation column made from scrap materials. A distillation column is an indispensable assistant for creating pure alcohol at home. Distillation column diagram.

The purpose of the article is to analyze the theoretical and some practical aspects of the operation of a home distillation column aimed at producing ethyl alcohol, as well as to dispel the most common myths on the Internet and clarify points that equipment sellers are “silent” about.

Rectification of alcohol– separation of a multicomponent alcohol-containing mixture into pure fractions (ethyl and methyl alcohols, water, fusel oils, aldehydes and others) having different boiling points, by repeated evaporation of the liquid and condensation of steam on contact devices (plates or nozzles) in special counter-flow tower devices.

From a physical point of view, rectification is possible, since initially the concentration of the individual components of the mixture in the vapor and liquid phases is different, but the system tends to equilibrium - the same pressure, temperature and concentration of all substances in each phase. When in contact with a liquid, the steam is enriched with highly volatile (low-boiling) components, while the liquid is enriched with less volatile (high-boiling) components. Simultaneously with enrichment, heat exchange occurs.

Schematic diagram

The moment of contact (interaction of flows) of steam and liquid is called the process of heat and mass transfer.

Due to the different directions of movements (steam rises up and liquid flows down), after the system reaches equilibrium in the upper part of the distillation column, it is possible to separately select practically pure components that were part of the mixture. First, substances with a lower boiling point (aldehydes, ethers and alcohols) come out, then those with a high boiling point (fusel oils).

State of balance. Appears at the very boundary of phase separation. This can only be achieved if two conditions are simultaneously met:

1. Equal pressure of each individual component of the mixture.
2. The temperature and concentration of substances in both phases (vapor and liquid) are the same.

The more often the system comes into equilibrium, the more effective is the heat and mass transfer and separation of the mixture into individual components.

Difference between distillation and rectification

As you can see in the graph, from a 10% alcohol solution (mash) you can get 40% moonshine, and the second distillation of this mixture will yield a 60-degree distillate, and the third – 70%. The following intervals are possible: 10-40; 40-60; 60-70; 70-75 and so on up to a maximum of 96%.

Theoretically, to obtain pure alcohol, 9-10 consecutive distillations are required on a moonshine still. In practice, distilling alcohol-containing liquids with a concentration higher than 20-30% is explosive, and due to the large expenditure of energy and time, it is not economically profitable.

From this point of view, rectification of alcohol is a minimum of 9-10 simultaneous, stepwise distillations that occur on different contact elements of the column (nozzles or plates) along the entire height.

Difference	Distillation	Rectification
Organoleptics of the drink	Preserves the aroma and taste of the original raw materials.	The result is pure alcohol, odorless and tasteless (the problem has a solution).
Output strength	Depends on the number of distillations and the design of the apparatus (usually 40-65%).	Up to 96%.
Degree of fractionation	Low, substances even with different boiling points mix, this cannot be corrected.	High, pure substances can be isolated (only with different boiling points).
Ability to remove harmful substances	Low or medium. To improve quality, a minimum of two distillations are required, with at least one of them being divided into fractions.	High, with the right approach, all harmful substances are cut off.
Alcohol losses	Tall. Even with the right approach, you can extract up to 80% of the total amount while maintaining acceptable quality.	Low. Theoretically, it is possible to extract all ethyl alcohol without loss of quality. In practice, at least 1-3% losses.
Complexity of technology for implementation at home	Low and medium. Even the most primitive apparatus with a coil is suitable. Equipment improvements are possible. The distillation technology is simple and straightforward. A moonshine still usually does not take up much space when in working order.	High. Special equipment is required, which cannot be manufactured without knowledge and experience. The process is more difficult to understand; preliminary at least theoretical preparation is required. The column takes up more space (especially in height).
Danger (compared to each other), both processes are fire and explosion hazards.	Thanks to the simplicity of the moonshine still, distillation is somewhat safer (subjective opinion of the author of the article).	Due to complex equipment, when working with which there is a risk of making more mistakes, rectification is more dangerous.

Operation of a distillation column

Distillation column– a device designed to separate a multicomponent liquid mixture into separate fractions based on boiling point. It is a cylinder of constant or variable cross-section, inside of which there are contact elements - plates or nozzles.

Also, almost every column has auxiliary units for supplying the initial mixture (raw alcohol), monitoring the rectification process (thermometers, automation) and distillate selection - a module in which the vapor of a certain substance extracted from the system is condensed and then taken out.

One of the most common home designs

Raw alcohol– a product of distillation of mash using the classical distillation method, which can be “poured” into a distillation column. In fact, this is moonshine with a strength of 35-45 degrees.

Reflux– steam condensed in the dephlegmator, flowing down the walls of the column.

Reflux ratio– the ratio of the amount of phlegm to the mass of the distillate taken. There are three streams in an alcohol distillation column: steam, reflux and distillate (the final goal). At the beginning of the process, the distillate is not withdrawn so that enough reflux appears in the column for heat and mass transfer. Then part of the alcohol vapor is condensed and taken from the column, and the remaining alcohol vapor continues to create a reflux flow, ensuring normal operation.

For most installations to operate, the reflux ratio must be at least 3, that is, 25% of the distillate is taken, the rest is needed in the column for irrigating the contact elements. The general rule is: the slower the alcohol is sampled, the higher the quality.

Contact devices of the distillation column (plates and nozzles)

They are responsible for repeated and simultaneous separation of the mixture into liquid and vapor, followed by condensation of the vapor into liquid - achieving a state of equilibrium in the column. All other things being equal, the more contact devices there are in the design, the more effective rectification is in terms of purifying alcohol, since the surface of phase interaction increases, which intensifies the entire heat and mass transfer.

Theoretical plate– one cycle of leaving the equilibrium state and achieving it again. To obtain high-quality alcohol, a minimum of 25-30 theoretical plates is required.

Physical plate- a really working device. The vapor passes through the layer of liquid in the plate in the form of many bubbles, creating a large contact surface. In the classical design, the physical plate provides approximately half of the conditions to achieve one equilibrium state. Consequently, for normal operation of a distillation column, twice as many physical plates are required as the theoretical (calculated) minimum - 50-60 pieces.

Nozzles Often, plates are installed only on industrial installations. In laboratory and home distillation columns, nozzles are used as contact elements - specially twisted copper (or steel) wire or dishwashing mesh. In this case, the reflux flows in a thin stream over the entire surface of the nozzle, providing maximum contact area with steam.

Nozzles made from washcloths are the most practical

There are a lot of designs. The disadvantage of homemade wire attachments is possible damage to the material (blackening, rust); factory analogues are free of such problems.

Properties of the distillation column

Material and sizes. The column cylinder, nozzles, cube and distillers must be made of food-grade, stainless, safe when heated (expands evenly) alloy. In homemade designs, cans and pressure cookers are most often used as a cube.

The minimum length of the pipe of a home distillation column is 120-150 cm, diameter is 30-40 mm.

Heating system. During the rectification process, it is very important to control and quickly adjust the heating power. Therefore, the most successful solution is heating using heating elements mounted in the lower part of the cube. Supplying heat through a gas stove is not recommended, since it does not allow you to quickly change the temperature range (high inertia of the system).

Process control. During rectification, it is important to follow the column manufacturer’s instructions, which must indicate operating features, heating power, reflux ratio and model performance.

The thermometer allows you to accurately control the process of fraction selection

It is very difficult to control the rectification process without two simple devices - a thermometer (helps determine the correct degree of heating) and an alcohol meter (measures the strength of the resulting alcohol).

Performance. It does not depend on the size of the column, since the higher the drawer (pipe), the more physical plates are inside, therefore, the better the cleaning. Productivity is affected by heating power, which determines the speed of steam and reflux flows. But if there is an excess of supplied power, the column choke (stops working).

The average productivity of home distillation columns is 1 liter per hour with a heating power of 1 kW.

Effect of pressure. The boiling point of liquids depends on pressure. For successful rectification of alcohol, the pressure at the top of the column must be close to atmospheric - 720-780 mmHg. Otherwise, as the pressure decreases, the vapor density will decrease and the evaporation rate will increase, which may cause the column to flood. If the pressure is too high, the evaporation rate drops, making the device ineffective (there is no separation of the mixture into fractions). To maintain the correct pressure, each alcohol distillation column is equipped with a communication tube with the atmosphere.

About the possibility of homemade assembly. Theoretically, a distillation column is not a very complex device. The designs are successfully implemented by craftsmen at home.

But in practice, without understanding the physical foundations of the rectification process, correct calculations of equipment parameters, selection of materials and high-quality assembly of components, the use of a homemade distillation column turns into a dangerous activity. Even one mistake can lead to fire, explosion or burns.

In terms of safety, factory-made columns that have passed tests (have supporting documentation) are more reliable, and also come with instructions (which must be detailed). The risk of a critical situation comes down to only two factors - proper assembly and operation according to the instructions, but this is a problem with almost all household appliances, and not just columns or moonshine stills.

Operating principle of a distillation column

The cube is filled to a maximum of 2/3 of its volume. Before turning on the installation, be sure to check the tightness of the connections and assembly, shut off the distillate selection unit and supply cooling water. Only after this can you start heating the cube.

The optimal strength of the alcohol-containing mixture fed into the column is 35-45%. That is, in any case, distillation of the mash is required before rectification. The resulting product (raw alcohol) is then processed in a column, obtaining almost pure alcohol.

This means that a home distillation column is not a complete replacement for a classic moonshine still (distiller) and can only be considered as an additional purification step that better replaces re-distillation (second distillation), but neutralizes the organoleptic properties of the drink.

To be fair, I note that most modern models of distillation columns require operation in moonshine still mode. To switch to distillation, you just need to close the connection to the atmosphere and open the distillate selection unit.

If both fittings are closed at the same time, the heated column may explode due to excess pressure! Don't make such mistakes!

In continuous industrial installations, the mash is often distilled immediately, but this is possible due to its gigantic size and design features. For example, the standard is a pipe 80 meters high and 6 meters in diameter, in which many times more contact elements are installed than on distillation columns for the home.

Size matters. The capabilities of distilleries in terms of still cleaning are greater than with home rectification

After switching on, the liquid in the cube is brought to a boil by the heater. The resulting steam rises up the column, then enters the reflux condenser, where it condenses (reflux appears) and returns in liquid form along the pipe walls to the lower part of the column, on the way back coming into contact with rising steam on plates or nozzles. Under the action of the heater, the reflux becomes steam again, and the steam at the top is again condensed by the reflux condenser. The process becomes cyclical, with both streams continuously in contact with each other.

After stabilization (steam and reflux are sufficient for an equilibrium state), pure (separated) fractions with the lowest boiling point (methyl alcohol, acetaldehyde, ethers, ethyl alcohol) accumulate in the upper part of the column, and those with the highest (fusel oils) accumulate at the bottom. As selection proceeds, the lower fractions gradually rise up the column.

In most cases, a column in which the temperature does not change for 10 minutes is considered stable (selection can begin) (the total warm-up time is 20-60 minutes). Until this moment, the device works “on itself,” creating flows of steam and reflux that tend to equilibrium. After stabilization, the selection of the head fraction begins, containing harmful substances: ethers, aldehydes and methyl alcohol.

A distillation column does not eliminate the need to separate the output into fractions. As in the case of a conventional moonshine still, you have to assemble the “head”, “body” and “tail”. The only difference is the purity of the output. During rectification, the fractions are not “lubricated” - substances with boiling points close to, but at least a tenth of a degree different in, do not intersect, therefore, when the “body” is selected, almost pure alcohol is obtained. During conventional distillation, it is physically impossible to separate the yield into fractions consisting of only one substance, no matter what design is used.

If the column is set to the optimal operating mode, then there are no difficulties in selecting the “body”, since the temperature is stable all the time.

During rectification, the lower fractions (“tails”) are selected based on temperature or smell, but unlike distillation, these substances do not contain alcohol.

Return of organoleptic properties to alcohol. Often, “tails” are required to return the “soul” to rectified alcohol - the aroma and taste of the original raw material, for example, an apple or grapes. After the process is completed, a certain amount of the collected tailings is added to pure alcohol. The concentration is calculated empirically by experimenting with a small amount of product.

The advantage of rectification is the ability to extract almost all the alcohol contained in the liquid without losing its quality. This means that the “heads” and “tails” obtained in a moonshine still can be processed in a distillation column and produce ethyl alcohol that is safe for health.

Flooding of the distillation column

Each design has a maximum speed of steam movement, after which the flow of reflux in the cube first slows down and then stops altogether. The liquid accumulates in the distillation part of the column and “flooding” occurs - the cessation of the heat and mass transfer process. There is a sharp pressure drop inside, and extraneous noise or gurgling appears.

Reasons for flooding of the distillation column:

• exceeding the permissible heating power (most common);
• clogging of the bottom of the device and overfilling of the cube;
• very low atmospheric pressure (typical of high mountains);
• the network voltage is above 220V - as a result, the power of the heating elements increases;
• design errors and malfunctions.

Fans of making homemade alcoholic beverages eventually come to the need to improve quality. The best solution is to obtain pure alcohol and dilute it according to the required recipe.

A rectification column will help you obtain pure alcohol. More recently, information about home rectification was inaccessible; today a large number of specialized forums and blogs cover in detail the process of home rectification and the construction of corresponding equipment.

Rectification is the process of purifying alcohol from light ethereal and heavy fusel components, ridding the product of glucose, sugars and acids. The rectification process allows you to obtain pure ethyl alcohol up to 96°.

The resulting raw materials are used for technical and medical purposes, as well as for the preparation of high-quality alcohol.

Reference. In order to make a device with your own hands without errors, you need to understand the physics and chemistry of rectification processes.

Raw alcohol or mash is heated in a cube. The vapor rises along the drawer, the heaviest parts condense at the bottom of the packing and flow into the cube. Easier vapors rise above the packing, condense and flow into the cube. A new portion of vapor rises, heats the already flowing phlegm, light fractions evaporate from it - the fundamental principle of heat and mass transfer comes into force.

The lightest particles reach the Dimroth refrigerator, where they cool and drain. When the vapors in the distillation column are “lined up” on floors in accordance with density, alcohol selection begins at the top of the column. Beginner rectifiers make a mistake precisely at this stage - either they allow “choke” - excessive reflux, or they take away a lot of product, then the “storey” suffers and the resulting alcohol will contain impurities.

Making a distillation column at home is quite difficult. Serious manufacturers calculate and test their products in detail and include detailed instructions. The DIYer has a choice:

1. Repeat the idea of ​​popular manufacturers, copy an existing device. If necessary, changes and modifications can be made to the tested diagrams.
2. Design your own scheme, different from others.

What does a distillation column consist of, and its drawing?

A home craftsman can make a drawer distillation column. It forgives many mistakes, and the result will be guaranteed.

Distillation column drawing

Alembic

This is a container where heaters are built in and mash or raw alcohol evaporates.

Capacity Specifications:

1. Strength. The weight of the distillation pipe will rest on the lid, so the cube must be rigid.
2. Chemical neutrality to alcohol. The ideal material is food grade chromium-nickel steel (stainless steel).
3. Convenience. The container needs to be lifted, moved, and stillage drained from it (distillation). The volume of the container is calculated depending on the required performance of the device and the power of the heaters.
4. Insulation. Heat loss should be minimal. therefore, both the walls and the bottom should be “packed” in insulation without cold bridges.

Drawer drawer for moonshine still

The drawer is a pipe that is installed on a cube. In fact, this is the main frame of the distillation column. There is a plate-shaped drawer, but it is rarely used at home.

Characteristics:

1. Strength. The wall thickness of the drawer is usually taken from 1 to 1.5 mm. This creates sufficient strength with low weight.
2. Chemical neutrality.
3. Insulation. In order to arrange pairs of different factions “by floor” in a column, the drawer must be well insulated. A sleeve made of foamed polypropylene or polystyrene foam trays used in plumbing are ideal.
4. Collapsible. For ease of cleaning and storage, the drawer can be made collapsible - from 30-40 cm elbows. This will allow you to adjust the height of the device, which affects the speed and quality of the product.
5. Availability of viewing glass areas.
6. Diameter. If it is a thin tube (up to 2 inches), no packing is needed - all processes take place on the walls. Such a column is called a film column. Diameters higher require the use of a nozzle - a sealing packing to increase the heat and mass transfer area.

Packing or nozzle

Packing is needed to sediment the phlegm and re-evaporate it. The main characteristic of padding is area. Stones of certain types, a stainless steel sieve, and stainless steel strand spirals are used as packing.

There are many ready-made solutions on sale; home craftsmen have come up with various inexpensive substitute options. Most often, metal dishwashing mesh or metal shavings are used to replace factory packings.

The alignment of vapors across floors depends on the volume and density of the nozzle. If the column uses a fine chip prismatic nozzle, you need to make a lattice support so that the nozzle does not fall into the cube.

Dimroth cooler

At the top of the distillation column there is a cooler - a tube twisted into a spiral.

Cold water circulates through it. It completely cools all light vapors. Characterized by plane of inclination, power, length.

Selection unit

It serves to select alcohol from the upper “floor”. The selection is not carried out completely; most of the phlegm returns to the tsar. The ratio of the product taken to the reflux returned to the tank is called the reflux ratio.

The higher the reflux ratio, the lower the productivity of the apparatus, the purer the product.

There are three types of selection:

1. According to the mash. the selection unit is located above the Dimroth refrigerator and catches the escaped vapors. They are further cooled in an additional flow-through refrigerator.
2. By liquid. The cooled phlegm of the “upper floors”, dripping from the refrigerator, is taken through inclined planes or a sump.
3. A couple at a time. Part of the steam rises upward to the Dimrot, and part of it rushes to the additional refrigerator, where it condenses. A stable reflux ratio is ensured, which does not change during the entire distillation time.

Additional refrigerator

Has an auxiliary function.

What is he doing:

• further cools the resulting product,
• precipitates random vapors,
• cools the finished product.

You will learn more about what a distillation column is and what the principle of its operation is in this video:

Design selection

The size and design of the device depends on a number of factors:

1. Required performance. with higher productivity, the padded drawer will be higher and wider - the pair passes 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.
2. 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.
3. 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. An excellent option for the DIYer is copper. It is easily soldered with a gas torch; there are a large number of them on sale.
4. 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.
5. 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.

For home distillation, the simplest would be a column with a cube of up to 50 liters with built-in heating elements with a power of 3 kW. Column diameter 32 mm, liquid selection unit based on the design of Alex Bokakoba, Dimroth refrigerator inserted above the selection unit.

An additional cooler is not needed; instead, a plastic tube 1.5 meters long, cooled by air, works perfectly. As a nozzle, you can use a Panchenko nozzle, SPN or metal stainless steel dishwashers. All connections are made using inexpensive plumbing threaded connections.

Optimal calculations

The column calculation begins with determining the following parameters:

1. Possible height. Practice shows that for a home device the optimal height is 1.5 - 2 meters. If a gas stove is used as a heater, the height of the drawer will be 1.2 - 1.5 meters. The diameter depends on the height, the average ratio is 1/50. For example, a drawer of 1.5 meters should be no more than 32 mm. (rounded up to standard pipes).
2. Power of the heating element or heater. A 1.5 meter drawer will have a capacity of approximately 300 ml/hour, which corresponds to 300 watts of heating element power. The heater power must be sufficient to heat the mash volume to 70 °C within 1 hour, and also be able to be optimally regulated.
3. Volume of a cube. This is an insulated container with a convenient size and transportable. To save room height, the diameter and height should be approximately the same. The amount of heated vapor depends on the volume of the cube. Beer kegs of 25, 30, 50 liters are convenient for home use. It is better not to use aluminum cans or tanks - aluminum quickly corrodes.
4. Coolers power. The cooler must fully cope with the condensation of vapors with minimal water flow. There is no exact formula for calculating the power of a cooler; the number of turns and length are selected experimentally. For our design, 30 centimeters of a tightly wound spiral from a 6 mm tube is sufficient. It is better to make a refrigerator with a power reserve and regulate the flow rate of cold water.

How to make plumbing fittings at home?

The steps are as follows:

• We purchase materials— 2 meters of 32 mm copper pipe; soldering tin; 15 cm of copper tube with a diameter of 8 mm, 2 meters of 6 mm tube; needle tap, plastic hose with a diameter of 8 mm. We purchase a ready-made nozzle or a substitute - ceramic gravel, metal sponge. The simplest connectors are clamps or brass threads.
• We make a king. We divide the pipe into sections of 1 meter, 0.3 meters, 0.5 meters. We solder a 10-centimeter piece to the lid of the cube, insert a mesh to hold the nozzle. At each joint we solder a clamp connection or plumbing thread made of copper or brass.

• Assembling the knot selection based on Alex Bokakob. On a tube 0.3 meters long, closer to the bottom edge, we make two corner cuts at 30 - 40 degrees. We insert copper plates into the cuts, cut them and solder them. We drill a hole for the liquid sampling tube; the hole should be at the bottom of the “pocket” of the bottom plate. On the extraction tube we solder a thread for a needle valve, which will regulate the extraction. We insert a “forward flow” tube to the side and just above the extraction hole. It is needed to control the reflux ratio. The direct flow conducts reflux from the selection “pocket” below, and the reflux drips into the center of the nozzle. The middle part of the forward flow is made of a transparent plastic tube.

• Assembling the cooler, for which we tightly wind a copper tube filled with sand onto a pin with a diameter of 12 mm. The pin is removed, the sand is shaken out and blown out. It turns out to be a spiral, one end of which needs to be threaded inside. The beginning and end of the tube are threaded into a brass “cup” with a thread and sealed - this is a stopper. The resulting refrigerator is inserted above the extraction unit, and the dripping reflux is collected by inclined planes.

• Before use, pour the nozzle into the drawer. The nozzle should not tightly clog the pipe; steam should pass through it freely.

• If desired, you can make a flow-through aftercooler. It consists of two tubes with a diameter of 10 and 12 mm. The length of the thin tube is 3 cm shorter than the thick one. The tubes are inserted into one another and the ends are sealed. The cold water inlet and outlet are soldered to a thick tube.

The column is assembled and ready for use. Before use, it is better to wash the parts with a weak solution of acetic acid using a brush.

Watch the video that shows how to assemble a distillation column with your own hands:

Operating modes

The modes are as follows:

1. Heating the mash to 72 -75 °C. The Dimroth cooler operates at minimum power.
2. Warming up the column and building “floors” of reflux condensation. Throughout the entire column there is active bubbling and steam and mass exchange. It is important to prevent oversaturation of the column, otherwise there will be “choke” - phlegm will clog the entire diameter of the drawer. We select the power of the heaters so that the temperature near the sampling unit is 71 - 75 °C.
3. Start of selection. When sampling by liquid, the slender pyramid in the drawer is inevitably disrupted, so the reflux ratio will need to be adjusted. The vapor density gradually decreases, and the intensity of selection also decreases. The first liquid selected—the “heads”—contains volatile ethereal components. The volume of the heads reaches 20% of the planned alcohol content.
4. Selection of main commercial alcohol goes until the smell of fusel oils appears.
5. If you want to extract everything possible from raw materials, we pull out the “tails” - the last part of the alcohol-containing vapors. They contain a large amount of fusel oils; the tails are mixed into “heads” and used in further rectifications.
6. Completion of rectification— turning off the heater, cooling the pipes.

The entire cycle, depending on the desired product quality, can last a relatively long time - from 8 hours to 2 days.

The average productivity of the column we assemble is 250-300 ml. 96° alcohol per hour.

Is it necessary to design the equipment?

The process of calculating, assembling and testing homemade equipment brings great pleasure. The result after edits and improvements will be guaranteed. However, the first difficulties or failures can cool the ardor of beginning rectifiers.

As a result of independent design, even minor nuances influence the result - packing density, angle of inclination, diameter of Dimroth tubes... If you need a quick and guaranteed result, it is better to purchase a ready-made device from the manufacturer. When purchasing, it is important to know the device, productivity and purpose of the device, so as not to buy a fake or ineffective device.

The Russian genius who wants to regularly taste alcohol in its pure form does not sleep - this is how they see a person who has assembled a homemade distillation column with his own hands.

But, in fact, this is absolutely not true!

With the help of a distillation column, you can obtain such delicious drinks as absinthe, whiskey, you can prepare flavored alcohol, etc.

Previously, rectifiers were a multi-meter column, but today’s version with “multi-pass” rectification makes it possible to reduce the height of the column.

If you are not confident in your abilities, then it is better to buy a distillation column in an online store, for example, the Dobrovar series allows you to obtain 98% alcohol from the first distillation.

However, let's return to how to make a homemade distillation column with your own hands.

We provide you with a simple way to prepare a rectifier at home. The appearance of the structure is provided in the first image. In addition, drawings of the rectifier are provided.

To begin with, I would like to talk about why the overgrown moonshine device is the most successful design.

Firstly, this device is unique, since it only requires a supply of running water. You can regulate the temperature of the boiler using a light switch, which has a smooth adjustment. You can use a homemade distillation column with any container, from a three-liter jar to an installed pressure cooker.

Let's look at the diagram of a distillation column made at home.

Distillation column drawing

As you can see, the design is quite simple. The refrigerator and water jacket can be made from a copper pipe by wrapping it around the rectifier pipes. You can make them from thicker diameter pipes than we used in our column. In this case, you need to solder the lower and upper parts to the walls. The remaining part needs to be insulated - for this you need to visit the construction market and purchase insulation for metal pipes.

Scourers are iron sink scourers that are cut with scissors. As a rule, sponges are made of stainless steel, which do not deteriorate during the operation of the distillation column. For a pipe 130 cm long and 35 cm in diameter, you need to use 15-20 washcloths.

The medical IV clamp must be used in conjunction with the tube. The tube will serve as a connection with the atmosphere - this is a classic syringe needle.

The height of the distillation column, which is shown in the drawing, is 130 centimeters (the height of the distillation cube - soldering iron is not taken into account).

Now a little theoretical knowledge.

Rectification is a reusable distillation of distillate, which is carried out in countercurrent packed and plate columns with contact components (plates, packings, etc.).

For the successful operation of reflux flowing down the column and steam moving upward, you can use any contact components that increase the efficiency and area of ​​their action. Trays are usually used as contact components in large distillation columns.
Each plate that is located in the column is called a FT - a physical plate. Its purpose is to ensure rapid movement of the equilibrium state between the vapor phase and the liquid.

The plates work in this way: steam in the form of bubbles with a sufficiently developed surface acts through a layer of reflux, which is located on the plate. As a result, mass exchange between phases intensifies.

It is worth noting that when steam passes through one plate, equilibrium between the different phases is not achieved. The actual state of the liquid and vapor phases in relation to their state is assessed only by the coefficient of correct action of such a plate.
The efficiency of a conventional plate is 50-60%, that is, to achieve a state of complete phase equilibrium, which theoretically corresponds to one plate, two physical ones are required.

Thus, it turns out that to create a 40-TT distillation column, it is necessary to install about eighty plates of a conventional design in it.

For distillation columns assembled at home with a diameter of 30..50 mm, the effective contact component is a special nozzle, which fills the internal volume of the column. When the column operates downward, the distillate flows down the contact filler, and the steam rises upward.

In industrial distillation columns, a “SULZER” nozzle is used, made of stainless, corrugated mesh or stainless wire in the form of small springs of a spiral-prismatic nature.

Heat-mass exchanges at the contact connecting parts occur continuously along the entire height of the column. The phase equilibrium position equivalent to the 1st theoretical tray (“TT”) occurs after the vapor overcomes the packing layer—transfer unit height (“TUP”) or the height of the theoretical tray (“TUT”).

This height is measured in millimeters, which in turn allows you to calculate the height of the future column. Therefore, in the manufacture of an installation at home, we are talking about columns that have a diameter of 30 - 50 mm, using packed contact components.

And this is what a purchased distillation column looks like in “full kit.”

Despite such an abstruse theory, a homemade distillation column is a very simple product!

Vadim speaks:

Maybe the pipe diameter is 35mm and not cm???

Vadim speaks:

And I also have a question, why do we need a connection with the atmosphere?

Marat speaks:

Good article...
The topic is not only covered, but the written information is well received, thank you!

Sergey speaks:

Vadim, when the column reaches the operating mode, the clamp from the medical dropper is closed and if there is no connection with the atmosphere, excess pressure will occur and subsequent destruction of the equipment.

George speaks:

But what if instead of washcloths you place a ribbon spiral in the form of an auger...then how to calculate the pitch of this spiral?

Igor speaks:

Good evening, can I look at the schematic drawing? And what gaskets should be used at the connection points? Thank you.

Artem speaks:

Georgy, why don’t you like iron washcloths?

Nikolay speaks:

Where can I buy an inexpensive river column?

Anatoly speaks:

pipe: dia. 50mm, length 1.6cm, cannot be used without washcloths. Cause?

Vladimir speaks:

I understand that not everyone has the opportunity, but...
A good result can be obtained by using the head of an old distiller. As a rule, their TENs and cubes fail earlier, and the heads are simply thrown away.

Alexander speaks:

Help me figure out what the difference is between a distillation column and a distiller (such as Volzhanin or Kum). That is, the alcohol selection is below the reflux condenser or like Volzhanin?

Paul speaks:

To reduce the height of the column, place an additional refrigerator in the work area (where the washcloths are), and adjust the temperature during distillation.

Fedor speaks:

That is, washcloths, in this case, replace plates?

Ilya

A distillation column today is considered an ideal assistant in cases where it is necessary to obtain pure and high-quality alcohol. Such devices are successfully used not only in industry, but also in everyday life. When using a column, it becomes possible to separate liquid mixtures with different boiling points. Let's look at how to make a household rectifier at home.

1 The role of rectification in moonshine brewing

When starting to produce moonshine and other drinks at home, many are faced with the concept of a “distillation column.” What is it for? How to use it at home? Is it possible to make a design with your own hands? – it is quite difficult for a novice moonshiner to answer these questions right away, especially since the operating principle of the device is one of the most complex in moonshine brewing.

The first thing to do is to understand the function of the device. So, the main task of the apparatus for creating alcohol is to separate liquids, provided that they have different boiling points. Thanks to this, at home we get high-quality moonshine or pure alcohol, which is in no way inferior to alcohol produced at the factory. If the rectifier container contains compounds with the same boiling point, then it will not be possible to obtain more or less high-quality alcohol, since the whole essence of the apparatus is the evaporation and separation of liquids.

The operating principle of the rectifier is based on a chemical process. The liquid that is at the bottom of the container begins to boil, as a result of which it rises up the apparatus. In this part of the system there is a reflux condenser, in which liquids with different compositions are separated. One of them is selected and goes further, and the second returns back to the container.

Thanks to the important function performed by the distillation column, this design will become an indispensable assistant for creating pure alcohol at home. With its help, you can prepare other home medicines.

2 Household rectifier - preparation for the manufacture of the device

Having understood the principle of operation of the device, you can begin to create it at home. We will need stainless steel pipes with a diameter of up to 45 mm. Their length should not exceed 120 cm. We will make a dephlegmator for separating alcohol from a thermos with a volume of no more than 1 liter. We will also need adapters for connecting the reflux condenser, pipes and distillation tank of the unit. For all these parts you should choose stainless steel.

Buy insulation that will help create stable thermal insulation for all components of the device. We will make the support washers for the device from sheet steel. For the thermometer bushings, we will take a piece of fluoroplastic, and as water outlets we will use thin copper tubes with a diameter of no more than 5 mm. After preparing the materials, you need to make a detailed drawing. The diagram of a distillation column for alcohol should be as detailed as possible, but at the same time understandable to you. The drawing should indicate the dimensions of the device, the location of holes and fittings.

In addition, in the drawing, specify the diameter of the pipes and adapters to them, the insulation material and the volume of the thermos. Do not forget to include in the device diagram the dimensions and direction of the water drainage pipes. A do-it-yourself distillation column cannot be made without certain equipment. Some of it can be found at home, the rest will have to be borrowed or bought. By the way, in order not to forget certain tools, it is better to include them in a separate list in your drawing. So, to make a device for creating moonshine at home, we will need:

• electric drill with a set of drills;
• emery machine;
• file, pliers and hammer for cleaning and bending stainless steel;
• electric soldering iron with a power of at least 100 watts;
• flux and solder;
• burner;
• regular or electronic thermometer;
• tap adapters;
• flexible tube at least 10 cm long.

If at least one of these tools is missing, it will not be possible to make a rectifier for alcohol. Therefore, it is worth preparing them in advance so as not to waste time during the search process.

3 Creating a device from a regular thermos

After we have drawn and checked all the drawings, collected all the tools and materials we need, we can begin making an apparatus for preparing alcohol at home. It is worth noting in advance that we are faced with a complex and responsible operation, which can only be performed if you have experience in working with a soldering iron and other devices for processing stainless steel.

A do-it-yourself distillation column is made using a special algorithm, which we will consider. First you need to cut off a piece of pipe, chamfer it and trim the edges. Next, we need to make an adapter with which we will connect the column tube and the distillate selection unit. The adapter should fit into the pipe as tightly as possible, and in the other part have a thread of 2–2.5 mm. Thus, we will achieve automation at the stage of vapor condensation.

After creating the adapter, we proceed to the washers. The diameter of the parts must be such that they eventually fit securely into the pipe. In most cases, the size does not exceed 4 mm. A pipe must be inserted into one part of the washer, and an adapter must be soldered into the other part - the junction of the element with the distillation tank. Next, insert the adapter into the pipe and heat the soldering area with a torch. After this, you can make a filler for the rectifier. Pour the material into the pipe and shake the part vigorously. This way the filler can be evenly distributed throughout the column. At the same time, it is worth making sure that our structure is filled to the top with material.

Let's start creating a reflux condenser. To do this, take a thermos, clean its bottom with sandpaper, and then tin the bottom. Then we make a bracket from tin, and also make loops from steel wire. We insert the latter into the holes of the brackets and twist the joints with pliers. We clamp the free end of the wire with a vice and attach it to the wall of the thermos. Next, shake the thermos vigorously so that its bottom falls off by itself. After this, we grind the seam connecting the lid of the thermos and the flask. It is necessary to grind until a small gap appears at the seam site. Next, we pull out the inner flask from its upper shell.

To make a reflux condenser, you need to remove the bottom and vacuum lid of the thermos. We drill a hole in the center of the back side of the inner flask through which air will flow into the container. We clean and tin the hole, and then insert the tube into it. We solder the hole in the tube, and then make another hole in the bottom of the thermos. Place a flask on the bottom of the container. We solder the tube and the bottom of the thermos. We tin the selection unit and the neck of the thermos. We insert the extraction tube into the neck and solder it at the connection point.

Next, take a drill and drill holes in the top and bottom of the outer bulb. We insert tubes into them for supplying and draining water. Next, we drill a hole in the unit to collect the distillate. This is where we will place the thermometer sleeve. It can be either conventional or electronic. The main thing is to try to find a dish-shaped device. With such a thermometer it is more convenient to monitor temperature fluctuations.

As we have seen, making a rectifier at home is not an easy task. However, having completed the work, you will have the opportunity to produce pure alcohol, from which you can then prepare your favorite or rosehip moonshine.

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Manufacturers of homemade moonshine strive to ensure that their drink is clean from harmful fusel oils and without an unpleasant odor. To do this, they distill the product several times, as a result of which it is purified. And yet, the best way to produce alcohol and alcohol-containing drinks is to use a device with a distillation column. The principle of its operation and the possibility of self-production will be discussed in the article.

Like a moonshine still, a distillation column produces moonshine, only of a higher quality, purified. But first of all, it is intended for the production of pure alcohol 96%, which is used as a base in the preparation of various alcoholic beverages.
Alcohol is a product of rectification, during which the alcohol-containing mixture (mash, raw alcohol) is separated into separate fractions (methyl and ethyl alcohols, fusel oil, aldehydes) with different boiling points as a result of repeated evaporation of the original liquid and condensation of steam.

The distillation cube filled with alcohol-containing liquid is heated. During the boiling process, steam is intensively formed, which rises up the column. There a reflux condenser awaits him, in which the steam is cooled and condensed.

Did you know? The largest distillation columns reach 90 m in height and have a diameter of 16 m. They are used in the oil refining industry.

Drops of condensate (reflux) flow down into a column filled with steam. The cooled reflux flows through special nozzles where it meets hot steam. Heat and mass transfer occurs between them, which is repeated many times and is the essence of rectification.

As a result, pure vaporous alcohol collects at the “head” of the column. For final condensation, it is taken to the refrigerator, from which the distillate, that is, the finished product, comes out.

Video: distillation column and the principle of its operation

Construction of a home distillery

The distillation column device consists of different parts, the dimensions of which must be accurately calculated. For this design you need:

• distillation cube, or container with alcohol-containing liquid;
• tsarga, or pipe, which will be the body of the column;
• a reflux condenser in which steam is cooled and condensed;
• nozzles with which to stuff the drawer;
• distillate selection unit;
• water refrigerator;
• smaller parts for connecting parts of the structure and for monitoring its operation (thermometers, automation).

Let's consider each component part of the device separately.

The basis of the entire structure is the distillation cube. This is a container for alcohol-containing raw materials.

It can be any vessel made of copper, enameled or stainless steel. Some moonshiners use a pressure cooker for this if a small alcohol yield is expected.

Or you can independently weld a suitable container from stainless steel sheets.

Video: how to make a distillation cube with your own hands The main requirements that the cube must meet:

• absolute tightness: when boiling, the vessel should not allow steam or liquid to pass through, and the lid should not be torn off due to growing pressure;
• a hole for steam to escape, which will appear if you cut a fitting into the lid.

If you buy a ready-made distillation cube, it already meets these criteria.
It is very important that the volume of the cube matches the dimensions of the column. For a pipe 1.5 m high and 50 mm in diameter you need to take a container that holds 40-80 liters, for a 40 mm drawer a 30-50 liter container is suitable, for 32 mm you need at least 20-30 liters, and for a diameter of 28 mm it’s excellent A pressure cooker will do.

Important! The distillation cube must be filled with mash no more than 2/3 of its volume, otherwise the column will “choke” when boiling».

The pipe in which rectification occurs is called the drawer. This is a cylinder with a wall thickness of 1.5 mm and a diameter of 30-50 mm. The effectiveness of the drawer depends on its height: the higher the pipe, the slower the harmful fractions are separated and the purer the alcohol is.

The optimal height of the tsar is 1-1.5 m. If it is shorter, then there will be no room in it for the separated fusel oils, and they will end up in the distillate. If the pipe is longer, the rectification time will increase, but this will not affect the efficiency.
Drawer of a distillation column with a nozzle There are ready-made drawers for moonshine stills with a length of 15 cm or more on sale. You can buy 2-3 tubes and connect them into one. Or you can make the drawer of the required length yourself. For this you will need a stainless pipe.

Video: how to make a drawer for a distillation column yourself You need to cut threads at the top and bottom so that the bottom part is attached to the cube, and the reflux condenser is attached to the top part.

You also need to attach a mesh to the bottom to hold the nozzles with which the drawer will be filled. Some home experts wrap the pipe with insulation, such as foam rubber.

Did you know? The Panchenkov nozzle was invented in the USSR in 1981 not for the production of alcohol, but to improve the purification of crude oil for aviation fuel.

Filling the drawer with nozzles is a prerequisite for rectification. If the pipe is hollow, only the distillation process is possible in it, the result of which will be moonshine, but not pure alcohol. The purpose of the filler is to increase the surface area over which reflux flows.

Thus, heavy harmful components are deposited and cannot enter the final product, and the light vapor of pure alcohol is selected. The filling should completely fill the tube.

The nozzle can be any filler made of inert stainless material:

• glass or ceramic balls;
• stainless steel kitchen sponges, finely chopped (they need to be changed from time to time, as the material deteriorates);
• Panchenkov nozzle (the best option), which is specially woven from copper or stainless steel. Its advantages: it settles phlegm well and does not fail over time.

Panchenkov nozzle

Important! The sponge attachment should be made of stainless steel. You can check it with a magnet: it attracts stainless steel.

The selection unit is a small piece of pipe between the drawer and the reflux condenser. Its purpose is to collect phlegm: first the “heads” come out, that is, the harmful alcohol fractions, then the “body” comes out, or alcohol without taste and unpleasant odor.
Everyone makes a homemade selection unit differently, but according to the same principle. Eg:

• to the outer pipe, the diameter of which corresponds to the diameter of the drawer, a tube of a smaller diameter is welded from the inside so that a pocket is formed between them along the circumference, where part of the reflux will be collected;
• Instead of a tube, a stainless plate is welded inside, corresponding to the inner diameter of the pipe, with a round hole inside: part of the reflux will collect on the plate, and part will fall through the hole back into the drawer.

Video: do-it-yourself selection unit Outside, two holes are made in the pipe for two fittings: a tap is attached to one to remove reflux, and a thermometer is inserted into the other (smaller) to measure the temperature of the steam.

The top of the structure is the reflux condenser. Here the steam cools, condenses and is directed downwards in the form of droplets.
You can make several options for reflux condensers with your own hands:

1. Jacket or direct-flow dephlegmator made from two pipes of different diameters. Running water circulates between them, and inside the smaller pipe the steam turns into condensate. The outer pipe can easily be replaced by a thermos body, the neck of which is screwed to the extraction unit. In the bottom of the thermos, you must make a hole for the TCA, that is, a communication tube with the atmosphere, through which light unnecessary vapors will escape.

   Video: operating principle of a direct-flow dephlegmator

2. Dimroth reflux condenser more efficient than the previous model. The body is a pipe of the same diameter as the drawer. Inside it is a thin tube, twisted into a spiral, in which cold water moves. If the diameter of the drawer is 50 mm, then the spiral needs to be twisted from a tube with a diameter of 6 mm and a length of 3 m. Then the length of the reflux condenser will be 25-35 cm.

   Video: assembly of a distillation column with a Dimroth reflux condenser

3. Shell and tube dephlegmator consists of several pipes: small ones are attached inside the large one, in which steam condensation occurs. This model has several advantages: water is used economically and steam is quickly cooled. In addition, this structure can be attached to the column at an angle, which reduces its height.

   Video: operating principle of a shell-and-tube reflux condenser

Fridge

A small refrigerator, or aftercooler, is needed to reduce the temperature of the ethylene flowing from the extraction unit. It is made according to the principle of a jacket reflux condenser, but from tubes of a smaller diameter.

It also has two passages for water: cold liquid enters the lower one, it leaves the upper one and is directed through silicone tubes up to the dephlegmator for the same purpose.

The water speed is controlled by the tap.

Video: how to make a refrigerator for a distillation column with your own hands

The pasteurization drawer is not a mandatory element of the column. On the one hand, it complicates the main design. But on the other hand, it improves it, since it more thoroughly purifies alcohol from the main fractions throughout the entire rectification.

This is a smaller drawer (30 cm) with an additional selection unit. It complements the main drawer. “Heads”, as usual, come out of the reflux condenser, but not only at the beginning, but constantly.

The alcohol is collected from the lower selection of a small drawer. This ensures maximum purity of the alcohol.

Automation

The long rectification process can last for hours. At the same time, it must be constantly monitored so that the “heads” and “tails” do not accidentally mix with the “body”. It will not be so tedious if you install good automation to control rectification. The BUR (distillation control unit) is designed for this purpose. The block can do the following:

• turn on the cooling water at a certain temperature;
• reduce power during reflux extraction;
• stop selection at the end of the process;
• turn off the water and heating after finishing sampling the tail section.

You can automate the process by installing a “start-stop” valve: when the temperature rises, it stops the selection, when it stabilizes, it resumes the selection.

You can do without automation, but it is much easier with it.

Video: automation for a distillation column

Advantages:

• the finished product is pure alcohol 96% without harmful impurities;
• in the distillation mode, you can make moonshine with the desired organoleptic properties;
• ethyl alcohol can become the basis of any alcoholic drink;
• You can design a device for this yourself.

Flaws:

• ethylene does not have the organoleptic properties of the original product;
• the rectification process is very long: in an hour you can get no more than 1 liter of distillate;
• ready-made structures are very expensive.

Which material is preferable

Rectification is intended for maximum purification of alcohol from various impurities. The parts that make up the column should not affect the quality or taste of the product. Therefore, the material must be chemically inert, not susceptible to rust and not affecting the taste and smell of the distillate.

Food-grade stainless steel, that is, chromium-nickel stainless steel, is best suited. It is chemically neutral and does not affect the composition of the product in any way.

The distillation column can be called a new generation moonshine still, because it produces better quality alcohol. Making this device with your own hands is quite difficult. But if you make an effort, the festive table will always be topped by a natural and tasty homemade alcoholic drink.

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