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Moonshine still baby drawings. The mash column is small. How does a film-type mash column work?

In terms of design, the mash column is something between a distiller and a full-fledged distillation column. From distillation column it has a reflux condenser, from the distiller there is a flow-through refrigerator for the finished product.

The mash column consists of two parts - a reflux condenser and a condenser. Each part has its own refrigerators, which operate autonomously and can be adjusted. Fine adjustments on the reflux condenser cooler are especially important. In homemade columns, you can install a valve-regulator from a heating battery on the inlet water pipe. It allows you to achieve fairly acceptable results.

Dephlegmator

It is a vertical section of a tube with a diameter of at least 22 mm and a length of 65-80 cm. In any case, the height should be 30 or more times greater than the internal diameter. At a lower height, the column will work, but the effect of its use will not affect the quality of the product. You should not get carried away with too high a height - the inertia of the device will increase and, consequently, energy consumption. The maximum d/l ratio should not exceed 45.

The reflux condenser is equipped with a refrigerator (in the upper part). This can be a coil wound on a column, a built-in coil or a water jacket (which is technologically more complex and is only available on devices industrial production). The column is installed on alembic strictly vertical. The upper part is connected to the condenser by a pipe; its structure will be discussed below.

In the upper part of the column (side wall) it is necessary to provide a socket for a thermometer. This is a mandatory attribute, without which it is impossible to work with the mash column.

Like a distillation column, a mash column works on the principle of heat and mass transfer between the flowing reflux and hot vapors rising from the cube. Similar processes occur in distillation column, but in the mash house they are as simplified as possible - there are no fillers, plates, attachments, etc. Reflux flows down the walls, so-called film heat and mass transfer occurs.

In translation, this means that phlegm, cooled to a certain temperature, flows down, is heated by vapor along the way, alcohol additionally evaporates from it and continues to move to the condenser, and high-boiling fractions remain liquid and flow into the cube.

Such a system assumes that the walls of the column will be cold enough and the reflux will not evaporate again. Therefore, unlike rectifiers, the column should not be insulated.

Capacitor

It is no different from the refrigerator of a conventional moonshine still - a distiller. Any design can be used. The steam enters the coil already purified of fusel oils and installing a steam steamer will not give any result.

How does a mash column work?

Steam from the distillation cube enters mash column and gradually fills it. When the temperature reaches 50-55 C (on the cube), the reflux condenser refrigerator turns on. The vapors condense on the walls of the column and flow down. Along the way they come into contact with steam, and the low-boiling fractions rise upward, entering the condenser through the steam line. The selection of goals begins.

When T=72 C is reached (at the top of the column), the selection of heads stops and a vessel for the main product is placed under the pipe. The selection of heads and the main distillation occur with a minimum level of heating and constant adjustment of the water flow in the reflux condenser.

The condenser refrigerator does not need adjustment. On the cube, the maximum temperature should not exceed 95 C. With rapid boiling, the column simply cannot cope with the separation of fractions and will turn into an ordinary distiller.

What's better?

The mash column has a number of undeniable advantages:

high level of alcohol purification (lower than that of a distillation column, but an order of magnitude higher than a dry steam tank);
relative simplicity of design (no more complicated than a distiller);
convenient to use.

In terms of energy consumption per unit of production, both types of devices are approximately equal, as well as in the cost of materials for independent production.

If you find a mash column in online stores, you can safely buy it. But only if its price is not much higher than the distiller. A reasonable difference is 10-15%. Many manufacturers offer mash columns at twice the price. This is economically and technologically unjustified. It's easier to do it yourself.

The process of distillation on a mash column will be interesting for both beginners and experienced moonshiners, allowing you to get a good product without much difficulty.

At the end of November 2010, I went to the website homedistiller.ru The reason was ordinary curiosity. But I became so interested in this topic that I ended up building this device. Together with members of the forum, I analyzed the principle of operation of one of the existing foreign devices, looking at its image in photographs, in a specially dedicated forum thread
It so happened that while considering a very expensive and advanced distiller, various assumptions about its operating principle arose in the imagination of forum members and new schemes appeared for a new device of a completely different design. I liked one of them so much that I wanted to make it myself. Compactness, ease of manufacture, minimal prices for components - all these factors further contributed to the realization of my dream. Thus, I became obsessed with this idea and began my journey of making an interesting product. I had to pick and buy everything necessary materials in stores, starting from the bottom part - a stainless steel tank and ending with the top part of the device - a glass jar with a steamer. And so, the day came when I assembled the model according to the diagram and tested it on water distillation. The first results were negative. It was necessary to analyze several options to resolve the issues that arose. And this path was overcome by me together with the forum participants. Thanks to my forum friends, I was able to improve the product, bring it to working condition, improving the current characteristics with each test. In addition to the creative work done, I learned new technologies for manufacturing various alcoholic drinks. This is how my little one was born alcohol mashine, which was named by the author of the scheme, forum member Leonid, by the nickname MOUNTAIN - the mash column Malyutka. After upgrading my first version, I carried out further tests. I understood how you can use this device to get a drink with a strength of more than ninety degrees. But since I do not pursue the goal of making a drink of such strength, I decided for myself to make it no more than eighty degrees. In this case, the distillate retains the taste of the original raw material, for which I use invert sugar fermented with wine yeast. The drink turns out wonderful in every way. Chemical composition, three samples, made in the chemical laboratory of St. Petersburg, allows you to use this product without risk to life. The results are published, answer 594, at:

At the end of November 2010, I went to the website homedistiller.ru
The reason was simple curiosity. But I became so interested in this topic that I ended up building this device.
Together with members of the forum, I analyzed the operating principle of one of the existing foreign devices, looking at its image in photographs, in a specially dedicated forum thread http://homedistiller.ru/forum/index.php?topic=13314.0
It so happened that while considering a very expensive and advanced distiller, various assumptions about its operating principle arose in the imagination of forum members and new schemes appeared for a new device of a completely different design. I liked one of them so much that I wanted to make it myself. Compactness, ease of manufacture, minimal prices for components - all these factors further contributed to the realization of my dream.
Thus, I became obsessed with this idea and began my journey of making an interesting product. I had to select and buy all the necessary materials in stores, starting from the bottom part - a stainless steel tank - and ending with the top part of the device - a glass jar with a steamer.
And so, the day came when I assembled the model according to the diagram and tested it on water distillation. The first results were negative. It was necessary to analyze several options to resolve the issues that arose.
And this path was overcome by me together with the forum participants. Thanks to my forum friends, I was able to improve the product, bring it to working condition, improving the current characteristics with each test.
In addition to the creative work done, I learned new technologies for making various alcoholic beverages.
This is how my little moonshine still was born, which was named by the author of the scheme, forum member Leonid, by the nickname MOUNTAIN - the mash column Malyutka.
After upgrading my first version, I carried out further tests. I understood how you can use this device to get a drink with a strength of more than ninety degrees.
But since I do not pursue the goal of making a drink of such strength, I decided for myself to make it no more than eighty degrees. In this case, the distillate retains the taste of the original raw material, for which I use invert sugar fermented with wine yeast.
The drink turns out wonderful in every way. The chemical composition of three samples, made in the chemical laboratory of St. Petersburg, allows the use of this product without risk to life. The results have been published, answer 594, at: http://www.homedistiller.ru/forum/index.php?topic=13314.580
Now anyone can assemble this mash column with their own hands. The assembly sequence is described in detail at: http://forum.homedistiller.ru/index.php?topic=13314.640

Brass columns are very common among lovers of strong drink. If you decide to make such a design yourself, then you need to familiarize yourself with the technology for carrying out the work and find out what features the device should have.

Preparatory work

The best mash column must have a certain height. You can pick up this parameter independently, but ideally it should be 50 diameters. According to experts, this is not so important; the equipment owner himself must decide what strength the product will have, and also decide how good the separation will be. However, there is a certain objective criterion that determines the smallest height of the manufactured column. You must avoid the possibility of splashing. Based on this, mash columns are not made below 30 centimeters. Otherwise, carrying out the work will be inappropriate.

Work technology

When manufacturing the described structure, it must be equipped with a controlled reflux condenser. Design features of this item may vary depending on your preference. The element can be created based on a shirt or dimrot. The main condition is the fact that the dephlegmator must have the ability to extinguish the power that is planned to be supplied. This element can be installed not in one quantity, but in quantity 2 or 3. In this case, the element will be primary or secondary. This structure allows for more stable operation of the column. You must understand that such additions are only possible on tall structures.

Work methodology

The mash columns must be able to adjust the cooling of the reflux condenser; this component must be quite thin. To do this, you should stock up on a tap that will allow you to use the liquid as accurately as possible. Experts recommend using the needle type, but you should avoid using a ball valve, as it is completely unsuitable. If we consider the available household solutions, the most the best option To carry out this adjustment work, a radiator tap will be used, which is used when installing a heating system.

You can prepare the drawing of the mash column yourself. The column must be equipped with a place for installing a thermometer, which is mounted in front of the condenser entrance. This statement is true for structures that will operate according to a steam extraction scheme. If a liquid withdrawal dephlegmator is used on a film column, the location of the thermometer will be determined by the specific design of the system. The mash columns are equipped with a refrigerator-condenser, which will be responsible for condensing and cooling the supplied steam. If the design has liquid extraction, then a refrigerator will be required that will lower the temperature of the finished product.

It is important to take into account during manufacturing that the supply of liquid to the reflux condenser or to each of them, as well as to the refrigerator, must be done separately. The tubes that will be used for the outlet of the refrigerator and reflux condenser must be used exclusively on a silicone basis. This statement is true for products hot water. If we are talking about cold water, then you can use polyvinyl chloride based tubes. The copper mash column must be made taking into account the above technical requirements, which are suitable for different Constructive decisions. However, you can not limit yourself and come up with your own modification. The main condition for this is that in the end you will be able to get your drinks, which will have different qualities and organoleptic characteristics. However, in the end it will not be possible to obtain pure alcohol. The final product will not smell like moonshine, but it will not be pharmaceutical alcohol either. But for making vodka, this design is quite suitable; the master will be able to start making the base for high-quality distillates.

Description of the manufacture of a column with a jacket reflux condenser

A continuous mash column can be made on the basis of a jacket reflux condenser. To carry out the work, you will need copper tubes, the length of which should be 500, 2000, 1000 and 300 millimeters. Each of them should have dimensions of 28 x 1.22 x 1.1 x 1.8 x 1 millimeters, respectively. Among other things, you will need a transitional double-socket coupling in the amount of 2 pieces, another transition coupling should have slightly different parameters, equal to 22 x 15 millimeters, 3 such elements will be needed. The master must prepare a single-socket corner, the dimensions of which are equal to 22 millimeters. It will be impossible to carry out the work without a tee, the dimensions of which are 15 millimeters. Be sure to make sure you have an adapter for a 1/2-inch external thread. You will need an adapter for 3/4" internal thread. The element will be required to attach to the cube, however in each specific case There may be other sizes. If you make a continuous mash column using the elements described above, you will end up with a product with a maximum temperature of 92 degrees.

Features of manufacturing an air-cooled device

A piece of copper pipe will be used to make a coil. A roll of aluminum-based wire will be used without insulation. You can use a computer cooler, superglue and a 500-watt boiler during the work. The power may turn out to be less impressive.

First you need to take a copper tube, bending it to connect to the body of the device. That part of this workpiece that will go down must be included in the spiral. should be wound onto the tube from above, leaving some distance between the turns. In order to reduce thermal resistance, the turns should be as dense as possible. This will increase the heat exchange area and the efficiency of the coil.

When making a mash column with your own hands, at the next stage you need to use any cone-shaped object, the diameter of which should be compared with the dimensions of the selected fan. You need to wind a moonshine coil onto this item. In this example, we will consider a regular beer bottle, the capacity of which is 0.5 liters. The coil must be bent so that it evenly covers the cross section of the fan. You need to try the element on the selected case and make sure that everything is in order. This concludes the work with the coil for now.

Now it’s time to move on to the lid of the device. To do this, you can use a regular polyethylene-based lid. The brass coupling must be heated to half an inch before fusing into the polyethylene cap. The structure must cool down; you can cool it in water. After the coupling is removed, it should be cleaned of adhering polyethylene, and the resulting burrs should be carefully cut off. You need to wrap a fluoroplastic tape around the coupling, which is essential for making a moonshine still. This way you will be able to get something like a gasket. When you make a mash column with your own hands, the next step is to install the coupling in a hole made in advance in the lid. The fluoroplastic should be between the coupling and the cover. WITH inside The nut should be tightened without applying excessive force.

At the next stage, you can work on the heating element of the entire device. For this you can use a regular boiler. Having retreated some distance from the end of the wire, so that it is enough to reach the device, you need to cut off a part, you will have to screw everything back afterwards. The ends of the cord from the boiler must be threaded so that when the lid is closed, the element is inside the body. After stripping the wires, they need to be connected back. It is important to take care of high-quality insulation.

The boiler should not touch the bottom; it is advisable that it be completely covered with liquid during operation. Into the same hole through which the boiler cord passes, you need to insert the long end of the coil for the apparatus. The remaining gaps between the tube and the cord must be filled with pieces of cotton wool, making it quite tight. It is important to achieve the best sealing possible.

The resulting structure made of cotton wool must be filled with superglue, which is made on a cyanoacrylic base. This will allow you to obtain the most airtight connection using composite materials. After the glue hardens, you will be able to get a tight, strong connection. All that remains is to make something like a casing for the fan so that the air washes over the fins of the heat exchanger, represented by a coil.

To make the casing, you can use Tetra-Pak packaging. If you are making a moonshine still, then you can use the technology presented in the article. You need to cut a rectangle from the packaging, the width of which will correspond to the dimensions of the fan. These elements will be used to cover the fan on 3 sides. The end of the coil needs to be brought to the fourth side in order to drain the moonshine. In the remaining side wall you need to make a hole for this part of the tube and glue it with the superglue used earlier. The walls can be glued together with tape. When it is necessary to ensure maximum safety, it should be covered with a transparent protective screen.

At this point we can assume that the mash column is ready. Can be used as a power source for the fan computer unit nutrition. To turn it on without using the motherboard, you need to connect the black wire with the green one. Experts use more compact 12-volt sources, which you can find yourself.

Deviation from the above requirements

If you are making a mash column with your own hands, the drawings of which you must complete in advance, then it is important to think about deviations from the mentioned requirements. The main one is an uncontrolled reflux condenser. If we are talking about the Malyutka column, then uncontrollability is sacrificed for compactness. To do this, the condenser and reflux condenser are located in a single container with running water. If you decide to use this scheme, then you will not be able to regulate the process using a reflux condenser, therefore, separation will not be achieved. If you are making a mash column with your own hands, you can borrow the drawings of this design from the article. It should also be remembered that the reflux condenser has low utilization capacity. You may encounter the problem of low column height. Some craftsmen cannot refuse to place the structure on a gas stove under the hood. In this case, separation will be quite difficult to achieve, which is especially true for tall columns.

The Rectify beer column has proven itself among lovers of strong drink. However, if you decide to manufacture such a design yourself, then it is best to use stainless steel-based parts. The fittings must be welded to the pipe, while an internal thread is installed on them on both sides, to which the keg necks are fixed. Using fluoroplastic, you can machine a sleeve-coupling, which will be equipped with a gasket for the clamp. All this will form a single whole. The mash column “Baby” must be equipped with insulating material, which is first cut along the length, then put on the pipe, on which it is glued. You should put a dephlegmator stick on the top cover and secure everything with a clamp clamp. The liquid will be fed into a tube through which the phlegm returns. You should put a piece on it that will prevent splashing to the level of the top plate.

Conclusion

If you cannot decide what you will make - a mash column or then you can make the first of them. It is easier to make and will also allow you to immediately start preparing a strong drink. As an alternative solution, you can try to purchase this device. Home craftsmen today sell them in completely different configurations and at different prices. From the available assortment you will choose something for yourself.

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).

Column continuous action retains the same stages of distillation 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 simple design. 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 light, low-boiling fractions from phlegm and leaves it with high-boiling heavy compounds ( fusel oils and water). The product of this long-term 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 of the device there is no need for automatic and 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 have decided to make a continuous mash column with your own hands and are 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 receive at the output?

If you have a small country cottage area with two tens 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 its most general form, the entire 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 get a quality drink that will truly be 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. You need to take four copper tubes of sizes 20, 12, 6 and 3 centimeters, five couplings with a transition to internal threads. Then twist the coil on which you want to wind aluminum wire for greater efficiency of the refrigerator 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.