If we analyze absolutely all moonshine stills that exist in nature, the distillation column is the most complex system. This is manifested both by its creation and maintenance. It is a special equipment for the production of alcohol. Its main purpose is to separate a liquid that has a high temperature regime. Quite often this device is used in industry.
It also happens that a moonshine still or a distillation column is made by hand, for personal use. Most often it is used for making moonshine. The main essence of the work is based on collecting alcohol or moonshine from the main liquid. Of course, it has a heating and cooling function, which is also incredibly important. With a distillation column, you have the opportunity to make alcohol yourself, without fear for its quality.
The principle of operation of the distillation column
Along the line of alcohol vapor, from the mash to the refrigerator, there is a node. It is called a distillation column - it is a kind of long pipe, the diameter of which is much larger than the length, about 40 times or higher. These dimensions are the most optimal for achieving the main purpose of the apparatus. Hot steam rises through the pipe to the surface, gradually loses temperature along the way, and flows down to the bottom back into the container.
During the movement, from the very top and to the bottom, it enters into contact with the steam and the temperature rises back, then all the components form steam again. Absolutely in all elements in the composition is present ethanol- the principle of operation of the distillation column is based on it. If you choose a certain system of column actions in such a way that alcohol vapors condense at the top, where a special fitting is placed, the purest alcohol enters the cooling mechanism. It will not contain any harmful chemicals.
After a certain period of time, a dynamic balance system is formed inside the column, due to the different temperatures of the watery and steam-water phases. In addition, the steam solution is divided into elements according to chemical formula required for the formation of steam. Vapors of unstable impurities accumulate at the top - aldehydes, acetone and other toxic elements. At a temperature in the column thermometer of about 70˚С, they simply fly out into the air - the column is connected to the environment by a pipe or valve, and actually functions under natural forces.
Approximately at a height of 3/4 of the length of the column, alcohol should form, which must be collected. Lower - oil and other elements, the boiling point of which is higher than alcohol. It is necessary to keep the temperature in the area of the release of the alcohol mass at about 76 ° C. In order to do this, a significant length of the column is required - the larger the area of \u200b\u200bdifferent parts, the easier it is to separate one element from the second.
Standard assembly method
Do-it-yourself distillation column is made on the basis of the scheme. The diagram is needed in order not to make mistakes. It contains not large volumes when compared with other devices that reach 19 meters. A distillation column made at home, its design and the mechanism itself cannot be characterized as easy - it consists of many components. Initially, you should buy a metal tube - its length is ideally about 119-149 cm.
Instead of a reflux condenser, it is allowed to use an ordinary thermos. In addition, you will need:
- adapters that will combine the tube with tanks;
- Insulation and stainless steel sheet for the production of main washers;
- A small reinforcing tube used to drain water;
- cooling mechanism.
From the devices you will need a hammer, a drill with a drill, pliers, a file, hard paper, a soldering iron with solder or flux, a transition device into a faucet, a rubber tube of small parameters and a temperature indicator.
A home-made device is produced according to the established scheme. The tube must have the desired length, and its tips must be polished. For the purpose of arranging the tube and the distillate unit, a euro adapter is used. The union of the pipe and the cube should be soldered, and part of the soldering later requires stripping.
Then you need to make metal nozzles that fill the pipe right up to the very top. Now the main washer is introduced into the pipe, a small end of the selection is introduced into it. The section of connecting points is soldered. The next step will be the thermal insulation of the pipe.
A thermos that will be used as a reflux condenser must be considered and removed from the bottom. The inner test tube must be removed from the outside and the vacuum cover of the thermos removed. A passage should be made in the test tube, in the central part of the very bottom of the part and in the main place of its rear edge.
Through the upper passage, you need to mount the pipe and seal it there. Then the base is placed on the cone.
In the outer flask, in addition, holes are made for the tubes for the entry and exit of water. They are located at the top and bottom of the tube. Zones in without fail fasten. In the distillate extraction unit, it is necessary to make a passage for the purpose of the temperature indicator bushing. The distillation column is created with special care so as not to harm your health.
In our generation, a small distillation column is quite relevant. This device is publicly available to absolutely everyone, and the device requires a little space. Drawing the industrial manufacture of a distillation column is a bit complicated for ordinary people. Nevertheless, the manufacture of alcohol at home occurs quite often, and many people practice it.
The distillation column model needs a large number of trays in order to obtain the highest quality product. This greatly complicates the installation process. To make this kind of apparatus, like a distillation column, with my own hands at home, you will need some details. The cooling mechanism is made from a reddish-yellow tube. In order to do this, it is necessary to wrap the rectifier column with it.
Iron washcloths are made from stainless steel. The period of validity and their reserve of use in the distillation column is quite long. In existing 9.8 cm pipes, you need to take 1 washcloth. A good idea, use a medical clamp with a dropper, you can take it instead of a tap. The scheme of the distillation column, as a rule, is completed with a tube, for the purpose of interconnection with the environment.
The essence of the column
If we briefly discuss the system of alcohol production and rectification, then this is, in fact, the repeated distillation of the mash, which takes place in special plates. Instead, they usually use all sorts of components. In order to produce alcohol at home, a distillation column with a diameter of 3 to 5 cm, an iron sponge can be used as a connecting component. It is through it that the distillation column for the moonshine will be filled.
During the operation of the distillation column, the distillate smoothly descends to the bottom, and the evaporation rises upward. A rectifier is needed in order to raise degrees. Separate modifications of this device involve the use of a boiler and a cool fluid jet in order to cool. All elements of the device may well be combined with each other using an ordinary soldering tool. Slight differences in volumes in the production of a unit so necessary in the economy will not particularly affect the quality of the product.
However, in order to increase the amount of alcohol, it is necessary to significantly increase the volume of the distillation device, a 1.5 m column tube, guarantees up to 28 liters of alcohol element, in about two days. Upon completion of the production of the apparatus, it is necessary to coat all connections with a detergent. In a similar way, it is allowed to examine the extra holes, if there are bubbles appear. When a water-steam cooler is connected to a tube through which water enters and whether there are holes during operation, it is a column-type system.
All of the above makes it possible to realize what kind of home-made device it is and why people need it at all. With a distillation column, you have the opportunity to get pure alcohol. In addition, we can conclude that it is not at all difficult to create an apparatus with your own hands - you just need to carefully read the instructions. It is also enough to have a strong desire, and the necessary details to create it. Everyone decides for himself what is better - to buy alcohol or make it at home, because in such moonshine there will be no harmful additives, and its quality depends solely on the distillation structure.
Attention, only TODAY!
Having familiarized myself with popular sites and forums on the subject of rectification, I decided to contribute to the common cause. Home craftsmen suffer with columns, hang a lot of automation on them. Pressure sensors, start-stop systems disrupting the entire rectification process, etc.
The main problems lie in low altitude, in incorrect calculations of installations, work on gas stove, orientation to the pressure in the column, and just a banal misunderstanding of the essence of the rectification process. And most importantly, everyone completely forgets that the correct column does not require automation. Automation is just an assistant.
The above scheme of the distillation column is one of the six options for solving the above problems. The "trick" is that it can be made low (super low) and get quite high-quality alcohol. I will make a reservation ... working on a gas stove is dangerous, the slightest mistake can lead to irreparable consequences - you are warned. The stability of the operation of a particular circuit solution lies in the so-called. storage tank under the dephlegmator displaced to the side, by adjusting the power supply (heating) in the cube, cooling and return of phlegm, you can get to a stable alcohol shelf with a height of the nozzle part of only 80 cm. There are no temperature saws in the column due to the impossibility of splashes on the thermometer sensor. The hydraulic level installed in the selection unit allows you to monitor the level of accumulated phlegm, which allows you to more accurately stabilize the process at the beginning of rectification and eliminates the overflow of the column during proper operation. The accumulative "glass" is borrowed from the well-known and eponymous device (the Soxhlet Extractor). Franz von Soxhlet
Developing design ideas, you can work with automation. Instead of a selection regulator, an electronic valve can be installed by connecting it through a comparator that takes temperature readings. Thus, the column turns into an ultra-small batch column with fractional selection. The comparator is programmed to open the valve at a certain temperature, the valve opens, the accumulated phlegm is drained into the receiving tank, after which the process in the column breaks down and the temperature rises, and the comparator works to close the valve. Of course, you can open and close with your hands, but the process is tedious. Thus, all substances can be selected on the column in turn, the process is described in more detail.
2.2. The device and operation of distillation columns,
Rectification of simple and complex mixtures is carried out in batch or continuous columns.
Batch columns are used in low-capacity plants where a large number of fractions must be collected and the separation must be high. The classical scheme of such an installation is shown in Fig. 4. The raw material enters the distillation cube 1 to a height of about 2/3 of its diameter, where it is heated with deaf steam. In the first period of operation of the distillation unit, the most volatile component of the mixture, for example, the benzene head, is selected, then, by increasing the distillation temperature, components with a higher boiling point (benzene, toluene, etc.). The highest-boiling components of the mixture remain in the cube, forming a VAT residue. At the end of the rectification process, this residue is cooled and pumped out. The cube is again filled with raw materials and rectification is resumed. The frequency of the process is due to the greater heat consumption and lower plant productivity. Further in the figure: 2 - distillation column, 3 - condenser-refrigerator, 4 - accumulator, 5 - refrigerator, 6 - pumps.
The installation of continuous action is devoid of many of these disadvantages. A schematic diagram of such an installation is shown in Fig.5. The raw material through the heat exchanger 1 enters the heater 2 and then to different levels of the distillation column 3. The lower fractions are heated in the boiler 4 and discharged back into distillation column. In this case, the heaviest part is removed from the boiler to the bottom of the column and together with the liquid sediment for further processing of heavy fractions. And the light fractions from above into the condenser-refrigerator 5, and then from the accumulator 6, partly back to the column for irrigation, and partly - to further processing of light fractions.
Depending on the number of products obtained, simple and complex distillation columns are distinguished. In the first, two products are obtained during rectification, for example, gasoline and semi-fuel oil. The latter are designed to produce three or more products. They are simple columns connected in series, each of which separates the mixture entering it into two components.
Each simple column has a stripper and a concentration section. The stripping or stripping section is located below the input of raw materials. The plate on which the raw material for separation is fed is called the feed plate. The target product of the stripping section is a liquid residue. The concentration or strengthening section is located above the food plate. The target product of this section are rectified vapors. For normal operation of the distillation column, it is necessary to supply irrigation to the top of the concentration section of the column and introduce heat (through the boiler) or live water vapor into the stripping section.
Depending on the internal device that provides contact between the ascending vapors and the descending liquid (reflux), distillation columns are divided into packed, tray, rotary, etc. Depending on the pressure, they are divided into high pressure distillation columns, atmospheric and vacuum. The former are used in the processes of stabilization of oil and gasoline, gas fractionation in cracking and hydrogenation units. Atmospheric and vacuum distillation columns are mainly used in the distillation of oils, residual oil products and distillers.
For uniform distribution of vapors and liquids in packed columns ax - 1 (Fig. 6.) as a nozzle - 2, balls, prisms, pyramids, cylinders of various materials (usually pressed coal dust) with an outer diameter of 6 to 70 mm and a surface area to volume ratio of 500 are used. placed in bulk on special plates - 4 with holes for the passage of vapor and draining phlegm - 3. The purpose of using the nozzle is to increase the contact area of phlegm and vapor for mutual enrichment. For the correct operation of the packed column, it is very important that the flowing reflux and vapors are uniformly distributed over the entire cross section of the column. This is favored by the homogeneity of the packing body, the highest possible velocity of the upward vapor flow, evenly distributed packing layers, and the strict verticality of the column. In practice, the initially achieved uniform distribution of vapors and phlegm is violated, since the vapor tends to push the liquid to the walls of the column and move through the center of the packing. In this regard, the packing is divided into several layers, and the plates on which the packing is placed have a special design that makes it possible to again evenly redistribute the flows after each packing layer. The efficiency of using packed columns is very high, but there are also inconveniences: the packing has to be periodically removed from the column in order to clean it from resinous particles covering the packing over time and worsening its wettability, in addition, the use of packed columns puts forward a very strict requirement to withstand a certain vapor pressure and the amount of incoming reflux . In the case of a drop in vapor pressure in the column, the reflux runoff accelerates and the area of contact between vapor and liquid decreases sharply. If the vapor pressure is exceeded, the flow of phlegm slows down, which leads to its accumulation in the upper layers of the packing and vapor locking in the lower part of the column (“flooding” of the column). This leads to an even greater increase in vapor pressure in the lower part of the column, and, at a critical moment, steam breakthrough through the phlegm into upper part columns. The consequence of the "flooding" of the column is also a sharp decrease in the area of contact between vapor and liquid.
In tray columns 1 (Fig. 7), in order to increase the area of contact between steam and reflux flows, a large number of plates of a special design are used instead of packing. The phlegm flows from plate to plate through the downcomers 3, and the baffles 4 maintain a constant level of the liquid layer on the plate. This level allows you to keep the edges of the caps 2 immersed in reflux at all times. The partitions allow only the excess of incoming phlegm to drain to the next plate. The principle of operation of the tray column is the mutual enrichment of vapors and reflux due to the passage of vapor under pressure from the bottom up through the reflux layer on each plate. Due to the fact that steam passes phlegm in the form of tiny bubbles, the contact area between steam and liquid is very high.
Plate designs are varied. Mesh, lattice, cascade, valve, injection and combined plates are used. The design of the trays is chosen based on specific technological requirements (the degree of clarity of fraction separation, the requirement for work intensity, the need to change the internal structure of the column, the frequency of preventive and repair work, etc.)
In some oil refining processes (for example, processing with associated separation of water (vapors), processing with preliminary separation of the heaviest oil fractions), rotary columns 1 (Fig. 8) with high productivity are used. The plates of such a column are conical shields with an inclination angle of 40°, with alternating plates fixed to the walls of the column - 2 and plates fixed to the central rotating shaft - 3. 
Thus, rotating plates alternate with fixed ones. The rotation of the plates comes from the drive - 4 at a speed of 240 rpm. The phlegm descends from above 5 along the fixed plate and at the center overflows onto the underlying rotating plate. Under the influence of centrifugal force, the phlegm moves up the rotating plate to its periphery and, in the form of a continuous annular film, passes to the walls of the column body and further to the underlying plate. Then the process is repeated. Vapors move through the phlegm in countercurrent. Besides a large number of phlegm is constantly in suspension, which leads to a high volatility of the phlegm itself. The distance between the plates is only 8 - 10 mm, which allows you to build a very compact column with a high (over 85%) efficiency. Heated raw materials are introduced into the column, the required temperature of which is maintained by a heater - 6. This design is very convenient to use, practically does not require repair and maintenance, is durable and not so sensitive to changes in temperature and pressure of the initial components.
Calculation of the amount of costs necessary for the implementation of this project in production. Assess the change in the cost of products obtained in the shop for primary oil refining and bitumen production. Two furnaces were installed in the workshop: for heating oil P-1 and for heating fuel oil and steam P-3; after reconstruction, a furnace should be installed that will completely replace both furnaces P-1 and P-3. Furnace performance by...
The quality of raw materials can be used gasoline (to produce liquefied gas); kerosene-solar fractions and vacuum distillates (for the production of gasoline, jet and diesel fuels); residual products of oil refining (to produce gasoline and jet and diesel fuel); gacha and paraffins (to obtain high-index oils); sour oils, sour and sour fuel oils (for...
The processes of separating oil into fractions, when its potential is used in terms of the range, quantity and quality of the products and intermediates obtained - oil distillation; secondary include the processes of destructive oil refining and purification of petroleum products, designed to change its chemical composition by thermal and catalytic action. With these methods...
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.
With a sufficiently large number of stages, 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 with atmospheric pressure, under vacuum, under 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 rectification is used to separate solutions that have low temperature boiling.
Consider operating principle of a distillation column, which is a part of a distillation unit of continuous action, intended for the separation of 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: to original product was preheated, the upper part of the column was continuously irrigated, 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.
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, various designs of trays and nozzles have been developed. 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 reflux layer 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 a constant steam velocity and 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 solids of various shapes (table with types of nozzles). 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.
In order for moonshine to turn out clean and without a characteristic fusel smell, it must be run through the apparatus at least twice. During distillation, most of the fusel oils, which gives reason to call finished product clean. However, experts insist that a truly pure alcohol-containing drink at home can only be obtained using a distillation column.
In order to understand how a do-it-yourself distillation column is made for a moonshine still and why it is needed at all, let's try to figure out the principle of its operation. Here we will consider what materials will be needed and whether it is advisable to make it at home.
How a distillation column works
When the distillation cube, where the mash is poured, is heated, a gradual boiling begins with an intense release of alcohol-containing vapor. These vapors, lighter than liquid, rise up the distillation column, from where they enter a water-cooled reflux condenser. Here, at the highest point, vapor condensation begins, and it again flows into the column in the form of condensate. That, in turn, is filled with special elements through which the liquid flows. At this time, the boiling of the mash continues, and its vapors rise up the column, meeting with condensate along the way. It is this continuous process of liquid and vapor exchange that is called rectification.
During such an exchange, the liquid condensate (phlegm) is saturated with steam, and the steam, on the contrary, is saturated with a liquid with a lower boiling point. This process occurs constantly while the mash boils and condensate forms. As a result, the lightest steam with the highest concentration of alcohol is collected at the head of the distillation column, which is discharged to the refrigerator for final condensation. Already from the refrigerator, absolutely pure distillate - moonshine - descends into the receiving tank.
The working principle of distillation column is shown in this figure
What is continuous rectification?
In order for the steam and the flowing liquid (phlegm) to contact most effectively, special contact elements are used in the distillation column. In industrial samples, this function is performed by physical plates, at home - a metal sponge for washing pans. These elements, due to the disparate structure, increase the contact area of phlegm and steam, and, accordingly, the effectiveness of such interaction. This becomes possible due to the fact that equilibrium is reached very quickly between the two phases (liquid and vapor).
In the process of phlegm flowing down the column, it bypasses a whole layer of metal springs, meeting steam along the way. At the moment when the steam overcomes the first layer of the contact element, the phase of physical equilibrium begins. To obtain the optimal height of a household distillation column, its diameter must be at least 30 and not more than 50 mm.
Production of distillation column
The issue of acquiring such equipment for many is very acute. If it's about industrial production, then in most samples there are many flaws. Still, streaming production makes itself felt. It is possible, as an option, to order manual assembly, but then its price will be approximately the same as that of the “wing” of a good SUV. Therefore, the best option is to make a distillation column with your own hands. Of course, its structure is slightly more complex than that of a home-made moonshine still, but still not so much as to lose consciousness from the drawing and instructions.
Stainless steel is suitable as a material for manufacturing - a chemically inert material that does not corrode and does not give foreign impurities and odor.
This is a diagram of a distillation column, according to which it can be collected
Now in more detail about the main elements of the equipment and what they can be made of.
- The body is a stainless steel pipe with a diameter of 30-50 mm and a total length of 1300-1400 mm. The allowable wall thickness of the pipe is 2-3 mm, since you will have to make holes for the threaded connection.
- Water case (reflux condenser) - most often made from an ordinary thermos. Literally 10-15 minutes, and this element will ideally replace the industrial design. In some cases, the reflux condenser is made of copper pipe. The most exotic and inefficient option is a coil made of copper tube. It is wound around the top of the column and launched over it. cold water. From experience, even a flattened tube does not provide the necessary heat loss due to the small contact patch.
- Refrigerator - a container with a submerged coil and cold water. The tank and tubes are made of copper. You can also purchase a ready-made laboratory refrigerator at the chemical store.
- The contact element is several metal mesh sponges, with which housewives usually remove scale and burnt food from pots and pans.
In addition, silicone connecting and copper tubes, thrust washers, threaded nuts, adapters.
There are 2 docking points in the column - a pivot point and a connection with an alembic. Usually, threaded elements are used for connection, but the danger here is in the flow. You can also put one element on another, while docking as tightly as possible in order to prevent the passage of steam and seepage of phlegm. You can, of course, treat the edges with sealant and dock the structure forever, but then you won’t be able to disassemble and clean it.
How to assemble a distillation column
- We take a copper pipe with a height of 1300-1400 mm and a diameter of 30-50 mm. We cut it into 2 parts, they can be either of equal length or with slight deviations - this is not important. The edges of both parts are cleaned, trimmed, be sure to chamfer and dock with each other with threaded connections or using an adapter. We remind you! The connection must be tight.
- On one part of the pipe, install a grid and thrust washers to prevent the contact element from falling out. This is the lower part of the column that will be put on the alembic. This is where the metal springs come in.
As such a contact element, not only springs, but also small glass balls can be used, although this is quite an expensive pleasure. Absolutely not inferior in terms of contact area and quality of heat transfer to ordinary metal sponges. Made of stainless steel, they are absolutely inert to the alcohol mass and are not subject to corrosion.
Before you buy such a sponge, check with a magnet whether it is really made of stainless steel. If another metal is used, over time the springs will begin to rust, which will negate the quality of moonshine cleaning.
- Buy 30-40 metal washcloths and cut them into small pieces up to 5 mm.
- In the lower part of the pipe, where the metal grid-fixer is installed, fill in the contact element, periodically tapping on the table. It is not necessary to push it forcibly, so that the springs, if possible, are not intertwined, but compactly compacted. So, shaking and tapping, fill the entire section of the pipe, then close it with a mesh and fix it with a thrust washer.
Already installed on the distillation cube, this part of the pipe should be insulated with any insulator, even foam rubber 3-5 mm thick will do.
- On the second part of the pipe, solder a water housing (deflector) with two pipes - one for the water inlet, the other for the outlet.
- From above, close the pipe with a lid or solder it by making a hole for the tube.
- At 15-20 mm from the junction with the lower part of the pipe, make a hole for the distillate outlet, and under it a small plate for collecting condensate - phlegm.
- Connect the column and the refrigerator with a silicone hose, on which a dropper clamp is installed - this is a very convenient tool for adjusting the movement of the liquid.
On this handmade production distillation column is finished, you can start distillation.
If you still have questions, in the video you will see how to make a column correctly and in what sequence.
