In simple language about the beer column. The best mash columns: description, principle of operation, design and reviews

Brewing alcohol at home is far from the easiest process imaginable. To do this, you will need not only high-quality ingredients, but also the appropriate equipment and the skills to use them effectively. In this article we will talk about continuous mash columns, which are also known as NBK.

NSC and their application

They are not very common today, although they have high level functionality. On the one hand, people are accustomed to using a standard still for distillation, so they do not want to adapt to something new. On the other hand, the cost of such a column is quite high and can reach several hundred dollars. This is why many people who make alcohol at home do not switch to mash columns. Our article is intended to describe this device, the principle of its operation, as well as the main advantages compared to the standard common method of still distillation. After reading the material, you can decide for yourself which method you prefer.

What it is?

So, first you need to understand what mash columns actually are. NBK is a device that allows you to obtain the purest raw alcohol from mash through steam generation. As you read this article, you will learn about absolutely all the features of this device and method of preparing homemade alcohol. It is worth noting that due to the high cost of the device and its components, this method is not so common in home distillation, but in industrial scale it has been used for quite a long time and is extremely successful. So if you really want to reach a new level of efficiency, then you should definitely pay attention to continuous mash columns, as they will allow you to achieve the desired result.

Device

Naturally, the dream of every home distiller is a mash column. Anyone can assemble this structure with their own hands (the drawings will help you with this). However, it is strongly recommended not to do this yourself, as this may lead to serious negative consequences and can even threaten your health and life. Further in the article we will present best models, which you can safely purchase right now - and then you won’t have to take risks and try to build something by hand. In the meantime, you need to understand the structure of this product so that you have an idea of what such a column consists of, and can also easily navigate the drawings if you still decide not to spend money, but to make the column yourself. So, the device is really not that complicated: the NSC consists of an evaporation tank, directly continuous column, pump, bardot vent, as well as some other parts that may vary from model to model - heater, power regulator, refrigerator, alcohol meters, and so on. Well, now that you know what this device consists of, you can create a mash column. There is no need to draw drawings yourself. You can use ready-made ones (one of them is presented below). The components, of course, will have to be purchased. You will also need to exercise extreme caution. And again we need to repeat: it is not recommended to take risks and make such a device yourself, as this is fraught with not the most pleasant consequences.

Operating principle

The mash column is an idea for those who want to quickly and efficiently obtain alcohol at home. But to use the NSC, you need to understand how it works, not just the design. Accordingly, now you will get acquainted with the process of producing alcohol from mash. The initial raw material, that is, mash, is slowly fed in a thin stream into the heater located on top of the device. Some models may not have this element, but with it the device works much more efficiently. From the heater, the mash enters the column from above, after which it gradually flows down plates located throughout the entire structure. At the same time, steam is supplied from the evaporation tank using a pump, which comes into contact with the descending liquid. As a result, all the vapors containing alcohol come out of it, and stillage reaches the bottom of the column, which is discharged into the sewer through the stillage drain. As for vapors saturated with alcohol, they rise higher and enter the distiller, where they already acquire their normal state of aggregation - liquid. That's all, raw alcohol of the highest quality is ready. As you can see, a continuous mash column works very quickly and efficiently, however, of course, a lot depends directly on the model of the device. Some options that you may consider will be presented to you later. In the meantime, you should familiarize yourself with the advantages of this device compared to the usual traditional distillation still.

A large amount of mash

Now that you can imagine a drawing of a mash column, and also have an idea of what is happening inside the device, you can draw some conclusions regarding the functionality of the NSC. The first is that the use of this device is perfect when you have any amount of mash. The fact is that a standard cube has a limited volume, so only a limited amount of mash can be poured into it, while in the NBK you can pour mash throughout the whole day. Accordingly, if you plan to make alcohol in large quantities, then this device is ideal for you. However, a mash distillation column has more than one advantage, so you should definitely consider each of them in order to fully realize how much more efficient and convenient home distillation will become when you purchase an NBK.

Convenience and order

Those people who have ever used a distillation cube know that after using it, a person will still have to clean it for a long time, since the stillage does not drain anywhere, and the cube must be washed after each use. If you have a mash column, then the stillage obtained during the distillation process is drained directly into the sewer through a distillation drain, saving you from the need to spend time and effort cleaning the stills every time. Thus, as soon as you decide that there is enough distillation for today, you just need to turn off the steam generator and stop feeding the mash. That's all, you can immediately go about your business, since there is no need to clean or put anything away.

Efficiency

While we're talking about saving time on cleaning, it's worth noting that you can spend less time on distilling in general. The fact is that the NSC uses heat recovery technology, which, in turn, provides an impressive increase in efficiency. Accordingly, you can get the same amount of finished alcohol in a shorter period of time, spending much less energy on it. As you can see, the advantages of the NBK are numerous, and you should consider and evaluate them all in order to be able to come to the conclusion that the mash column is the best assistant for any distiller operating at home.

Quality of the finished product in cube

All of the previous benefits are very pleasant, but none of them are so impressive as to force the distiller to switch from the traditional method to using a mash column. Of course, no cleaning required, can be processed more mash and easy saving of time and energy are pleasant bonuses. But the very advantage that is most important has not yet been touched upon. The fact is that when using NBK you can get raw alcohol of much higher quality and much purer. Why? It's actually quite simple. When you use the still method, the process of evaporating alcohol from the mash takes quite a long time. During this time, other chemical processes are launched, during which the yeast contained in the mash is “cooked,” as well as some other substances, which all ultimately give the finished alcohol product additional aromas and tastes. Naturally, when using high-quality equipment, these smells and tastes are barely distinguishable, but they are still present, which significantly reduces the organoleptic properties of raw alcohol.

Quality of the finished product at NBK

If you use NBK, then the process of evaporating alcohol from the mash occurs incredibly quickly - it takes a maximum of fifteen seconds. During this time, none of the side processes has time to reach such a stage as to give the alcohol-saturated steam its aromas and tastes. Accordingly, when using NBK, the raw alcohol obtained is as pure and high quality as possible, and this is what puts mash columns much higher than even the most advanced still.

NBK Vilenoff (6kW)

Now you will get an idea of what NBKs are available on the modern market. The product that we are going to talk about now is the best mash column that you can get your hands on. Its power is 6 kW, which allows the device to function more than efficiently. The unit has a fairly large height - just over two meters. The evaporation tank is located at the very base and has a volume of 93 liters. If we talk about the supply of mash, it is adjustable, that is, you yourself can control how much product will be supplied to the column. The maximum is 70 liters per hour, but you can reduce it to any level you wish. The approximate yield of raw alcohol is 13.5 liters per hour, but this figure is not stable - it largely depends on the quality of the mash you use. This NSC is the best column available to everyone, but it is far from the only one you can get.

NBK AR-480

The previous product costs more than six hundred dollars, and not everyone wants to spend such an impressive amount. So if you still want to purchase an NBK, but do not have such funds, then a mini-bar column may come in handy. It is much smaller in size, it lacks some elements such as the evaporator tank which you will have to attach separately, and it is also less efficient due to the fact that its power is only 2.5kW, which is much less than from the previous model. However, the device still remains incredibly functional, and most importantly, it will cost you only three hundred dollars, which is half the price of a full-size, highly functional NSC. Accordingly, you can choose one of these options - or go in search of some other option. Are you not interested in any of the bar columns? You can build an analogue with your own hands. And although this is not the best or safest option, you cannot simply ignore it and not say anything about it.

Creating an NBK with your own hands

The easiest way out is to purchase a ready-made device, but if you want to experiment, you can try it. Perhaps you will end up with a full-fledged mash column - it is quite difficult to make the device yourself, although everything may look simple in the diagram. As you already understood, you need to ensure that the top container, which can be, for example, an inverted glass jar, alcohol-saturated vapors came in, and spent stillage flowed down. Evaporation must occur in the fan pipe, which must be achieved at a certain temperature. If you understand such devices, then you will have a chance to build something similar. If not, then it is unlikely that you will get something quite effective, and most importantly, a homemade device is not always safe.

The main features of continuous mash columns, their disadvantages and advantages.

Relatively new technology distillation of mash, but has gained great popularity. The high quality of the resulting raw material and the autonomy of its operation make this column very interesting for distillers.
Principle of operation
Like most installations for home distillation, NBK came to us from industry. In Continuous alcohol production plants, a continuous mash column is located at the very beginning of the cycle; with its help, the mash is converted into raw alcohol. How does this type of equipment work? Water vapor is supplied to the column from below from a special device (steam generator); the mash is supplied by a special pump from above at a constant speed. The column itself is filled with contact elements, most often plates, on which the interaction of steam and mash occurs. At the bottom of the column there is a drain for stillage, at the top there is a condenser for the CC. The steam gives up its heat to the mash and turns into water, while the mash heats up and boils. Due to the small volume of mash in the column this process happens very quickly, the mash in the column boils for no more than a minute, during which alcohol and other impurities can be completely removed from it; under certain conditions, the output we get is moonshine and stillage practically devoid of everything except water.
It is unacceptable to use SPN and RPN as a nozzle, only plates. The on-load tap-changer and, even more so, the SPN will quickly become clogged with even yeast sediment and the operation of the NSC will stop, especially since the productivity of the packed NSC will be very low.
Advantages:
Autonomy of operation, with a constant stable supply of mash, the column will work until the water in the steam generator or mash runs out.
High quality SS. Due to the speed of squeezing alcohol out of the mash, the yeast membranes do not have time to burst and produce additional unpleasant odors.
Possibility of almost complete removal of tails. By adjusting the feed speed, the operator himself controls the temperature of the stillage. And additional mash condenses the tailings, working as a dephlegmator.
Eliminating the need to pour the mash into a cube and drain it. The mash is fed directly from the fermentation tank into the column, and then drained directly into the sewer.
Saving cooling water. T.K. For optimal operation of the NSC, it is recommended to preheat the mash; it is most optimal to do this with SS vapors coming out of the column, thus cooling water is required only for additional cooling of the resulting SS, which reduces its consumption.
No automation required. Due to the operating principle of the NBK, it does not require additional automation for operation, except for a stable supply of mash and heat; it self-stabilizes and operates within the specified parameters throughout the entire distillation process.
Possibility of use during the second distillation. The only need is to ensure the return of phlegm to the cube. The column has contact elements, so it can be used for the second still distillation, with the selection of heads, tails and obtaining a pleasant strengthening, which is enough to obtain a quality distillate. It is also easy to remove the block of plates and pour the packing into the column, thus obtaining the frame of the distillation column. (These features are relevant for , please check with them about the availability of similar capabilities from NBKs of other manufacturers)

Flaws :
Requirements for mash purity. Unfortunately, NBK is only capable of working with liquid mash, such as sugar, fruit and flour, while malt mash will have to be filtered.
A stable feed is required. For proper operation of the NSC, a pump with a stable supply of mash, the so-called, is required. dosing. Most a budget option - .
Consistent power required. If the power fluctuates, but it is not possible to achieve a stable spin of the mash.
Danger of heating element breakdown. Because Most often, a cube acts as a steam generator, that is, there is a danger of exposing the heating element when distilling large volumes, so you should carefully monitor the liquid level in the cube or use special steam generators with make-up.
The mash should not be foamy. In cases of distillation of foamy or unfermented mash, it is recommended to use a defoamer to avoid the release of mash into the selection.

conclusions
An excellent and quite versatile assistant for the home distiller who values his time and effort. It allows you to distill a significant volume of mash in a semi-automatic mode, with virtually no human intervention. Setup is required only at the beginning of the process and takes no more than 5 minutes. Thanks to the ability to fill the steam generator immediately hot water the start of the process is faster and saves electricity. During the distillation process, cooling water is saved. The result is pure moonshine with a surprisingly pleasant smell and taste. The design feature of our NSC allows you to hang it on the wall and use a gas-heated steam generator, supplying steam through a steam line.
Thank you for your attention, drink the right drinks.

The mash column is a recent invention used at home for distilling alcohol from any kind. This simple device has gained popularity among summer residents and owners of country gardens who use substandard fruits to prepare mash.

Home distillation has undergone a significant evolution in a relatively short time, moving from an ancient coil to a continuous column, which, according to its operating principle, is a simplified (home) version of a factory distillation column. What is a mash column and what is the principle of its operation?

What are the advantages and disadvantages of this device? Is it possible to make it yourself at home or is it easier to buy a ready-made one? Let's try to figure it out.

A mash column is a device designed for distilling alcohol from any type of mash and equipped with a reflux condenser - a device for partial condensation of the vapor of various liquids that arise during the distillation process.

The reflux condenser separates the vapors leaving the column into separate fractions, returning heavy condensate for further separation of alcohol from high-boiling organic compounds of the fermentation solution ( fusel oils).

A continuous column retains the same distillation stages as a conventional moonshine still equipped with a steamer: evaporation plus condensation. The difference lies in the principle of evaporation, which provides high-quality purification of the final product.

The continuous mash column, in accordance with the principle of operation, has a simple structure. It consists of the following key elements:

containers (tank, container, cube) for fermentation solution, having three threaded holes for installing a thermometer, outlet tube and safety valve;
columns made of copper pipe or stainless steel;
a reflux condenser, which is mounted at the top of the column;
nozzle for connecting to a condenser of any design (coil, shell cooler, etc.);
two thermometers, one of which is mounted at the top of the column, the second shows the temperature in the fermentation liquid container.

Various design modifications of this device may contain: silicone gaskets, clamp joints, adapter couplings of different diameters and bushings. The entire set of elements is usually given in the drawing specification.

Operating principle of a continuous mash column

Before starting the process, it is necessary to install a column with a distillation tank using clamp fasteners. Place the cube on a heat source (electric stove, gas stove etc.).

As the solution heats up, alcohol-containing vapors from the tank rise into the condenser, where they partially condense, settling on the walls of the refrigerator. The rest of the steam continues to move upward.

The first cooler is called partial precisely because it only partially condenses the steam. The settled liquid is called “reflux”, and the cooler, accordingly, is called a “reflux condenser”.

The reflux flows down the walls of the reflux condenser back into the tank, encountering uncooled steam on its way and breaking up into three types of fractions: head, main and tail.

The head fraction (head), including aldehydes, esters and other light substances, is cut off at low temperature at the initial stage. Then it comes to the main fractions (body), containing the alcohol itself, and at the very end of the process, the tail (tails) compounds from fusel oils and other heavy impurities are removed.

During the heating process, condensate fills the walls of the column, reaching the reflux condenser. This happens when the thermometer on the upper cooler shows 51 - 55 degrees.

At this stage, the vapors of light fractions complete condensation and are removed into a special container. This is a poisonous solution and is not used for further distillation. On average, 20 liters of moonshine yield one liter of head fractions.

As the tank heats up, the temperature at the reflux condenser reaches 77 degrees. This is exactly how it should remain during the entire distillation process. During this period, the main fractions—the alcohol itself—are separated from the fermentation vapors.

Fifteen minutes before the end of work, it is necessary to raise the temperature at the upper cooler to 81 - 83 degrees in order to collect “tails” - impurities of fusel oils and other heavy compounds, which are subsequently sent for the second distillation.

The operating temperature of the device is regulated by the top tap at the cooler inlet and the heat source regulator.

Did you know? The standard technological description of the distillation process looks like this: alcohol vapor rising to the reflux condenser continuously reacts with reflux flowing towards it. A heat exchange reaction occurs. Steam takes away the light, low-boiling fractions from the phlegm and leaves it with high-boiling heavy compounds (fusel oils and water). The product of this long reaction becomes alcohol with a strength of 88 - 90 degrees.

The quality of the output alcohol (purity of moonshine) is achieved by temperature control, which helps to separate the head and tail fractions of alcohol-containing vapor from the final product.

Important! For novice moonshiners, it is necessary to remember: during the distillation process, under no circumstances should the mash be allowed to boil. The temperature in the tank should not rise above 87 - 89 degrees;

Pros and cons of the distillation process in a mash column

pros

Simplicity of the distillation process: the device will work until the fermentation solution in the cube runs out and the water in the steam generator disappears.
Good quality of the final product. The short distillation time does not allow the yeast membranes to “explode” and introduce a fusel smell into the alcohol.
The reflux condenser makes it possible to almost completely remove heavy tailings, sending fusel oils to the tank for new distillation.
There is no need for additional operation: pour the mash into the cube and then pour it out. —The mash container is placed on the stove, then after work, the remaining solution is disposed of in household waste.
Economical use of water for cooling. During the distillation process, it is recommended that the fermentation solution be preheated, so that water is needed only to cool the product and for nothing else.
For continuous operation The device does not require automatic or semi-automatic control regulators. When supplying mash and heat, the device will operate stably in the specified mode throughout the distillation period.

Minuses

The device can only work with liquid mash made from sugar, flour solutions and - fruit mash—. Malt types of mash must be passed through a filter.
Frequent breakdowns of the tubular electric heater. Due to the large volumes of mash, there is a danger of it being exposed. This requires constant monitoring of the solution level in the tank.
Foamy mash cannot be used for distillation, since the foam is often thrown into the main fractions, which requires additional purification of the final product. - You can remove foam from the mash only with the help of a special defoamer.

How to make a column with your own hands

If you decide to make a continuous mash column with your own hands and already mentally imagining the drawings of the future device with all the dimensions, you need to moderate your ardor and stop in time to answer the questions for yourself: how often will you use the device and what volumes of alcohol do you intend to get at the output?

If you have a small summer cottage with two dozen fruit trees, then seasonal distillation will not require large expenses for making a simple continuous mash column with your own hands and according to your own drawings.

For a farm with a large orchard, you need a powerful machine with high productivity.

Finding drawings for making a continuous mash column with your own hands is not difficult. They are in specialized literature and on the pages of thematic sites on the Internet.

In order to get started, you need to purchase some equipment. Each drawing specification contains full list what you need to buy.

In the very general view the whole list looks something like this:

container for fermentation solution and evaporator (volume is indicated in the specification of each specific drawing) – 2 pcs.;
copper or stainless steel pipe with a diameter of 50 - 100 mm and a length of 1.5 - 2 meters - 2 pcs.;
thermometers – 2 pcs.;
silicone hoses (length is indicated in the specification of each specific drawing);
assembled cooler or separate parts for it;
clamp holder – 2 pcs.;
couplings, fittings (quantity and dimensions in the specification);
mesh filters and partitions (quantity and dimensions in the specification).

Did you know? It should be remembered that the cost of making a device with your own hands is not without common sense only if you have plumbing skills, as well as general engineering knowledge in the field of heating and electrical engineering.

However, if you wish, you can overcome the difficulties and make the device yourself to receive quality drink, which will be truly yours: from your harvest to your equipment.

After drawing up the drawings and purchasing the components, the work on manufacturing the device can be divided into the following stages:

Preparation of the column itself from a pipe (copper or stainless steel), the height of which must correspond to the dimensions of 50 diameters. Drill a hole for the column in the fermentation tank and prepare an outlet for clamp mounting. Then drill another hole in the tank for the thermometer and mount everything into a single system.
Manufacturing of a reflux condenser. Need to take four copper tubes sizes 20, 12, 6 and 3 centimeters, five couplings with transition to internal thread. Then twist the coil on which you need to wind an aluminum wire to make the refrigerator more efficient and make a cover for the reflux condenser. This can be an ordinary polyethylene lid for a jar, into which you need to melt a nylon sleeve in order to tighten the holder nut during installation. Mount the dephlegmator as a separate unit and only then connect it to the column.
Hole. You need to drill a hole in the column for the second thermometer, which should be located in front of the reflux condenser.
Assembly and installation of a refrigerator-condenser with a tap for water inlet and outlet. Install the tap using silicone gaskets as a single block and then attach it to the column through an adapter.

Listed here are the most necessary operations for the manufacture, installation and assembly of a mash column. However, many craftsmen are trying to improve the device. They include two, three and four dephlegmators in the general distillation system, install automatic relays for supplying water to the condenser cooler, and much more. Everyone decides for himself which device he needs.

The evolution from grandma’s coil to home distillation columns followed bizarre paths, producing many dead-end branches and “monsters,” but sometimes useful hybrid designs were developed. One of these devices was the mash column (BC), the popularity of which among home distillers is growing every year. However, such a device requires understanding theoretical foundations and proper operation, otherwise the result will be disappointing.

The history of the appearance of the mash column

What was wrong with the good old coil? Firstly, low performance. Secondly, even with fractional distillation, the distillate contains a significant amount of harmful impurities. A rectification column (RC) copes with these disadvantages, but has its own problems: expensive equipment; after rectification, the drink does not contain the smell of the original raw material, and a distiller is still needed for the first distillation.

The advent of once-through and shell-and-tube refrigerators solved the productivity problem. These cooler designs made it possible to relatively quickly distill the mash into raw alcohol, and to overcome splash entrainment, an empty pipe was added to the design. This is how the new generation distiller acquired its finished form.

Example of a once-through refrigerator

Example of a shell-and-tube refrigerator

The pipe served as a steam trap - preventing splashes from the cube, which are formed in wild phlegm, from entering the selection. Such a distiller easily coped with any heating power available in everyday life. There's also a slight product boost to reinforce what was previously thought. useful property– a reflux condenser was used, which gave rise to a whole family of distillers with strengthening, related by the common name: “mashing column”.

Attention! The continuous mash column (CBC), despite the similar name, has a completely different purpose and principle of operation.

Film mash column

The main one was the BC circuit with a jacket reflux condenser, shown in the figure.

Example film column assembled

Available materials, ease of manufacture and strengthening of moonshine up to 90-91% contributed to the growing popularity of this scheme. Based on operating experience, the basic requirements were formulated.

A film mash column was considered good if:

the diameter was 25-28 mm, and the height was from 30 to 50 times the internal diameter;
there was a sufficiently powerful and well-controlled reflux condenser capable of extinguishing the operating heating power;
there was precise regulation of the flow of cooling water to the reflux condenser using a needle valve;
a separate water supply to the refrigerator and reflux condenser has been implemented;
a thermometer is installed above the reflux condenser in the steam pipe;
there was a sufficiently efficient refrigerator to operate at full heating power in both the second and first stages.

Working with the film column was not easy and required constant attention from the owner. During the first distillation, the reflux condenser was not turned on so as not to increase the boiling time of the mash, but during the second distillation the reflux condenser was already working, making it possible to select the “heads” drop by drop and strengthen the “body” to 90%. True, it was not always possible to achieve the intended goals with the help of a reflux condenser, then heat regulation was used, which eventually became the main one for the BC. However, the product obtained as a result of distillation on film BC seemed to enthusiasts to be much better than moonshine after fractional distillation on a regular device.

Euphoria can be explained by the fact that high strength masks bad smell drink True, after diluting with water to 40-45%, all the shortcomings of the distillate became fully apparent after a couple of days. Users consoled themselves with the fact that they were not striving to obtain alcohol, but wanted to drink well-purified moonshine with the aromas of the raw materials.

Disadvantages of a film column

"Strong does not mean pure"- this simple thought did not immediately take possession of the minds of moonshiners, but there were sensible skeptics who gave the product for analysis. The results were amazing: laboratory testing showed that purification of impurities using this equipment is a myth.

Moreover, if the film column somehow made it possible to select the “heads,” then there were almost more fusels in the selection than in the original raw material. This made us think and understand how harmful impurities get into selection, then determine the reasons and try to overcome them.

1. Sensitivity to water pressure. Even a slight decrease in the water flow in the dephlegmator is enough for all the intermediate harmful impurities accumulated in the pipe to instantly slip into the selection. It is enough to open the tap in the bathroom or flush the toilet so that the water pressure in the system drops, and the drip-by-drop selection of “heads” turns into a vigorous stream.

Improvement proposals poured in as if from a cornucopia: stabilization with the help of pressure regulators, water supply through an intermediate tank under the ceiling or an aquarium pump, autonomous cooling systems, etc. In general, very useful things and applicable not only for BC.

It seemed that the problem had been solved, but in addition to stabilizing the flow of supplied water, it was also necessary to control the reflux ratio with its help, and this is very inconvenient due to the high inertia of the system.

2. Low holding and separating capacity. Trying to place coils or a couple of sponges into the column improved the situation a little, but not enough to solve the cleaning problem as a whole. As a result, the “heads” were selected carelessly, and even despite the drop-by-drop selection, the necessary esters responsible for the aroma were also removed along with harmful substances.

Due to the impossibility of concentrating “heads” in the selection zone in large quantities due to the practically non-existent holding capacity, it was necessary to select them in excess, losing a significant part of the alcohol. The transition to the selection of the “body” by increasing the heating power instantly sent the intermediate impurities accumulated in the pipe into the selection.

The situation was further aggravated by the fact that when selecting the “body,” the division dropped to 2-3 plates and could not detain the fusel fish. When the temperature in the cube approached 90-92 °C, if they did not switch to the selection of “tails” in time, the remains of the fusel fish flew into the receiving container, leaving only water in the “tails”.

Even in the best samples of moonshine produced on film columns, the content of fusel oils is at least 1-2 thousand mg per liter, more often it is much higher. Due to the design features of the film BC, the distillate turns out to be unbalanced - with a clear imbalance chemical composition towards the fusel.

The emergence of the modern mash column

The solution to the problem of clearing fusel oils came quickly - you need to fill the drawer with a nozzle. As a result, the BC turned into a mini RC ( distillation column) with the same rules and equipment requirements. The only differences remain in the versatility of the design, which allows the use of BC for distilling mash. Traditional BC steam extraction is also used, although many distillers appreciated the convenience of liquid extraction and installed it on their columns, while others began experiments with steam extraction before the reflux condenser.

Example of a mash column

After this, BC classic form film column with steam extraction above the reflux condenser solemnly marched to the Museum of the History of Moonshine, where it took pride of place. You can object: “It’s completely for sale!” The answer is simple: you never know the number of dealers and collectors of antiques who sell and bribe not only outdated items, but also their fakes.

Requirements for a good mash column

In most cases, a modern BC has a column with a diameter of 40-50 mm and a height of 75 to 100 cm, as well as a cube of 20-30 liters, liquid selection and automation. In general, this complies with the standards and requirements for the Republic of Kazakhstan, but the main thing remains for the mash column: the versatility of the design and the desire to obtain a well-purified distillate with the taste and aroma of the original raw material, which can be drunk immediately without long-term correction-aging in oak barrels.

However, during operation, ordinary users encountered a problem: using standard rectification technologies when distilling mash, they did not receive the expected well-purified and fortified distillate, but rather dirty alcohol, which was half-contemptuously called NDRF - under-rectified. It seemed that the evolution of the development of mash columns had reached a dead end.

Then BC fans began experiments on the use of low reflux ratios when distilling raw alcohol. Everything fell into place. Smaller volumes of still bulk and short drawers, which prevent the production of pure alcohol at the distillate, have become a strong point for the production of distillate. The high drawer of the RK has a separating ability that is excessive for the distillate, cutting off not only the excess, but also the useful.

The low frame of the BC made it possible to implement a technology for a balanced reduction in the concentration of all impurities in the product while removing some that are definitely not needed. This was also facilitated by the use of larger nozzles. So, for a 50 mm BC, an SPN of 4 x 4 x 0.28 is used instead of 3.5 x 3.5 x 0.25 in the BC. For certain tasks, dish-shaped columns and copper rings as nozzles have proven themselves to be effective, but this is a topic for a separate article.

How to work on a mash column correctly

Beginners often complain that despite all their efforts, they end up with pure alcohol in the mash column, and not delicious drink. There is no universal technology, since many of the nuances of distillation depend on the design of the apparatus, but by following the basic rules, you can make an aromatic and well-purified distillate using BC.

1. BK and RK are devices that implement heat and mass transfer technologies, therefore the requirements for preparing equipment for operation are almost the same for them. In order to confidently control the reflux ratio during operation, you need: stable, controlled heating and cooling, as well as good thermal insulation of the cube and column.

2. Calculate the planned selection rate of the “body”. We assume that the reflux ratio should not exceed 2. For example, if the operating heating power for a 50 mm column is 1700 W, then approximately 4.93 x 1.7 = 8.3 liters of liquid per hour evaporates from the cube. We must select a third, and return two thirds with reflux back to the column and cube. This means that the planned withdrawal rate is 2.8 liters per hour, and the reflux ratio is (8.3 -2.8) / 2.8 = 2. Greater accuracy is not required.

3. The long and dull selection of “heads” adopted during rectification removes not only aldehydes, but also esters responsible for the aroma of the drink. Therefore, the “heads” should be selected no more than 2-3% of the AC (absolute alcohol) in bulk. The speed should be approximately 25-300 ml/hour (about 10% of the “body” selection rate).

4. We set the starting speed of “body” selection equal to the planned one (in our example, 2.8 l/hour). And after the selection begins, we adjust it so that the output strength is 90-91% with a bulk strength of 40%.

We don’t change the speed anymore! By the end of the “body” selection, the speed will drop, and the strength in the stream will drop to 87-88% (with a residual strength of raw alcohol in the cube of 5%). The speed is enormous compared to rectification, but this is precisely what allows medium ethers and a moderate portion of higher alcohols to pass into the receiving container. The selection of the “body” must be completed at a bottom temperature of no higher than 95 °C.

5. If we distill grain raw materials, then we select the “tails” fractionally (2-3 servings of 100-150 ml each) at a speed two to three times lower than the starting speed when selecting the “body”. The “tails” will go the next day for blending or for further processing in the Republic of Kazakhstan.

The main thing is not to be afraid of a high selection rate: if you underestimate it, then the output will no longer be good distillate, but poorly purified alcohol, which is quite suitable for a barrel - impurities are not completely removed, but only “slightly combed”, freed from excess fusel and aldehydes.

If the goal is a distillate for consumption without long aging, then you can experiment with adjusting the reflux ratio, remembering that the higher the reflux ratio, the greater the degree of purification and approach to alcohol.

For the distillation of sugar raw materials, only maximum purification from all impurities and distillation technology adopted in the Republic of Kazakhstan are suitable. If the volume of the bulk does not exceed 15-20 volumes of the packing in the column, this SPN packing is of a size corresponding to the diameter of the column, and the column itself is at least 1 meter high, there is a chance of obtaining quite decent alcohol from raw sugar alcohol.

P.S. Thanks to the user from our forum for preparing the material for this article.

Continuous mash column NBK 6 kW (updated version) intended for production in large volumes high-quality moonshine or raw alcohol for rectification. The column's productivity is more than thirteen liters of moonshine with a strength of 50-55% vol. per hour, which is a very high figure compared to still distillation. Compared to the NSC, some changes have been made to its design to improve the reliability and stability of the NSC.

NBK equipment

Cube 93 liters
Brass column 80 mm
Bardootvodchik
Mash heater
Direct flow refrigerator
Parrot
Alcohol meters ASP-3

Technical characteristics of NSC 6 kW

NSC design 6 kW

This NSC is a vertical pipe with a diameter of 80 and a height of 1500 mm, in which twelve trays are placed, occupying approximately 1200 mm of the bottom part of the column. The mash is fed not from the top point of the column, but directly onto the top plate, having previously passed through a heater through which the steam coming out of the NSC is passed. The design of this continuous mash column uses two identical ones from the Optimum Prime construction set, one of which (the upper one) is used to heat the mash entering the column, and the second (the lower one) is used to condense and cool the resulting raw alcohol. In the design of this column, we abandoned the reheating of the mash with distilled stillage, which made it possible to significantly simplify and unify its design. At the bottom of the NSC there is a mash drainage unit, the design of which allows you to regulate the pressure in the NSC by changing the overflow level. The NSC does not need automation; a stabilized power regulator, for example, is sufficient, which, among other things, allows you to measure the pressure in the cube and the temperature at the required points of the NSC. All connections of the NSC are made on clamps, which speeds up and facilitates its disassembly, assembly and maintenance.