Belching 

What gives the tsarga without filler. How to make a distillation column - calculation of system parameters. How does the reflux process take place?

In a distillation column, you can fill up a different nozzle and it will work, but in different ways. When choosing a filler for a column, it is necessary to take into account its characteristics (pipe diameter, its height). Fillers for distillation columns are different, the most popular of them are: (SPN) Selivanenko spiral prismatic nozzle, (RPN) Panchenkov, Raschig rings, ordinary stainless steel kitchen washcloths, broken glass, etc.

The nozzle is necessary to keep the largest volume of reflux on its surface, as well as to allow the flow of alcohol vapor to pass freely. Interacting between failure phlegm and steam ensure the separation of the water-alcohol mixture into different fractions. Therefore, the larger the area at the surface of the nozzle, the better the separation will be.

1. SPN

Spiral-prismatic fillers have been invented quite recently. SPN Selivanenko was the first of them. Now some modifications of this nozzle have appeared, for example, the 10-sided SPN of Diogenes. Currently, the spiral prismatic nozzle is considered the best for use in home-brewed stills and distillation columns. For household brew columns and distillers, it is better to use copper SPN, according to some reports, it softens the taste of the distillate.

The SPN is made of stainless wire with a thickness of 0.2, 0.25 and 0.3 mm. Consists of segments 4x4; 3.5x3.5; 3x3 and 2x2 mm prismatic spiral. The smaller the packing, the higher the quality of the resulting product, but lower productivity, and with a large packing, the selection rate increases, but the separation quality is lower.

The nozzle is poured into the column and lightly compacted every 10 cm, for this it is convenient to use the handle of a shovel. For a household column, it is easier to purchase a nozzle from a trusted seller, because There have been a lot of fakes on the market lately. The price of the SPN Selivanenko nozzle is about 1500-2500 rubles per liter, 1 liter, depending on the type of wire, weighs about 1.2 kg.

You can make SPN with your own hands at home. To do this, you need stainless steel wire, a winding device (usually a drill or a screwdriver), and the finished cut nozzle must be pickled.

Video how to do SPN with your own hands

2.OLTC

The second most popular Panchenkov nozzle used in home distillers and homemade distillation columns to increase the strength and increase the degree of purification of alcohol. On-load tap-changer (regular wire nozzle) was created at OAO Tupolev. This packing is highly efficient and is used in many expensive household distillers and river columns.

Convenient to use, the rolled nozzle is easy to insert and remove from the column for cleaning. On-load tap-changer is woven from stainless thread 0.13 mm thick. Zigzag weaving, very thin, the gaps between the threads are not more than 1 mm. It is used in pipes with an internal diameter of at least 30 mm. The regular nozzle has proven itself in home distillers.

3.Rashig rings

Rashig rings made of ceramic, metal or glass with a rough surface to keep the phlegm longer on the surface. This type has long been used in distillation columns. Raschig rings are less popular, but nevertheless they are used in many devices as a nozzle.

4. Washcloths

The most budget option for the nozzle is the usual kitchen washcloths for sinks, which are sold in any supermarket. Usually they are made of stainless steel, so they will be suitable as a filler for columns. Of course, the quality of alcohol will be an order of magnitude lower, and during distillation, changes in the taste and smell of alcohol may occur from washcloths.

Quite often, a metal mesh can be found in the delivery set of one or another moonshine still. The purpose of this accessory for many remains a mystery. Today we will try to give an exhaustive answer to the question of what is a distillation column filler and in what cases it is reasonable to use it.

First of all, let's turn to the materiel and take a look at what is happening inside the moonshine still. Being installed on the hot surface of the stove, it begins to heat up, which leads to heating of the mash inside. Being brought to a boil, it begins to evaporate and in the form of steam rushes into the upper elements of the moonshine still. It does not matter at all what kind of moonshine is used. It is much more important to understand that this most saturated alcohol vapor contacts the surfaces of the steam pipes, where it settles in the form of reflux drops. This happens due to the temperature difference inside the device and outside. Drops of phlegm under their own weight begin the return journey and rush into the distillation cube. In other words, we have 2 multidirectional streams that move towards each other. In home brewing, these streams are called masses. Throughout their route, they interact with each other. Vapors saturate phlegm, and phlegm accordingly does the same only with respect to vapors. The more intense this process goes, the better the final product becomes. The intensity of the mass exchange process is determined by many factors, the most important of which is the area of ​​contact surfaces. The larger it is, the more phlegm can be collected and vice versa. At the moment, the advantage of distillation columns in relation to classical type distillers becomes obvious. For the latter, the area of ​​contact surfaces is minimal, while for columns it is significant. The advantage of the column in relation to distillers is the ability to increase the area of ​​internal contact surfaces. There are 2 options here: buy a hag or buy a so-called. column filler. As a rule, moonshiners are more willing to buy the filler, since it is much cheaper. Moreover, if it is available, you can not increase the height of the column.

The most common are Panchenkov's regular wire nozzles. Structurally, they represent a lot of threads woven into a kind of roller. This same roller is placed inside the distillation column, where it helps to collect phlegm.

You can also use Raschig rings or Selivanenko spiral-prismatic nozzles, but they are not used so often. This is due to the fact that they need an additional fixation mechanism so that during the distillation they do not fall into the distillation cube. As for the effect, it is almost identical to that in the case of Panchenkov's RPN.

Summing up the fillers for columns, it should be emphasized that they are all good in their own way. Each moonshiner decides for himself which filler to choose.

To get a high-quality alcoholic drink at home, you need the right equipment. A classic distillation cube is not enough for these purposes, since fusel oil vapors and volatile ethers enter the product along with alcohol vapors.

It is they who give moonshine a nasty smell, addiction and a hangover headache.

A radically new step in home brewing is the appearance of column-type apparatuses.

Important! On the distillation cube instead of a steamer is installed tsarga- a hollow tube stuffed with a fine stainless steel mesh or covered with small pieces of metal of a spiral-prismatic shape.

The essence of the improvement is in the principle of reflux.

Dephlegmation - the deposition of vapors and their flow into the cube:

  • An important process takes place in the tsarga - the "alignment" of vapors on the floors.
  • The lighter the pairs, the higher in the king they are able to break through.
  • We need heavy smelly fusel vapors to settle down, and pure alcohol vapors to rise up, where the selection unit is located.

The video tells in more detail what a tsarga is and why it is needed in a moonshine still:

Kinds

Tsarga is the basis for beer and film distillation columns. It is tubular and plate-shaped. The physics of phenomena in these devices is different.

In a tubular king vapors turn into condensate on the walls and surface of the nozzle. Vapors freely return back to the cube, evaporating along the way. The mechanism of heat and mass transfer works.

  1. The minus of this tsarga is the great length, bulkiness and complexity of building phlegm by levels.
  2. Plus - the simplicity of the device.

In a plate-shaped king vapors settle on the surface of the mesh. The vapors coming from below pass through the accumulated phlegm layer, bubbling occurs.

Phlegm passes light vapors, heavy vapors remain in liquid form. There can be from 3 to 12 plates, depending on the diameter and type of the side.

  1. The downside of this drawer is the complexity of manufacturing, the need for glass sections to control bubbling and the level of reflux on the plates.
  2. Plus - compact size, the highest quality products.

Nuances

For a skilled craftsman, making a tsarga with his own hands is not a problem.

To get a great thing, we need:

  1. Materials. Copper is better processed, but very expensive. Stainless steel will require the help of an argon welder, but stainless steel pipes are much easier to find. Brass plumbing joints are perfect as a connector for copper pipes, it is better to connect stainless steel with clamps.
  2. Tools. A roller pipe cutter will help to cut the pipe evenly, but it is not available to everyone. Therefore, we use the "grinder", sandpaper for cleaning burrs. To solder copper pipes, you will need a gas burner, solder and flux. Stainless steel will have to be welded either with a TIG machine or with special electrodes for stainless steel.
  3. Skills. It is not difficult to solder copper pipes - the theory of soldering can be found on specialized sites or from bloggers. Working with stainless steel is more difficult - it is very easy to make a hole when welding with an electrode, and welding with a non-consumable electrode in an argon environment requires experience and skill. Before carrying out work, it is better to practice on scraps or unnecessary pieces.

How to do it yourself?

Making a good wash or distillation column is a rather complicated and troublesome business. If it is possible to purchase a reliable and tested device from the manufacturer, the result will be more predictable.

The factory-made device is often not available due to the high cost. Making a tsarga with your own hands is more accessible and cheaper.

Calculation of length and diameter

Different capacities require the use of different pipe diameters and lengths.

Reference! For distillation - obtaining raw alcohol - a pipe 0.5 - 1 meter long is suitable. The diameter is not that important.

For rectification, the parameters of the tsarga depend on the required performance, heater power, cube volume. There are extensive formulas for calculations, as well as standard solutions. For a 3 kW, 40 liter cube, you will need a 1.5 meter long drawer with a minimum diameter of 3 inches.

For a home master, the most affordable will be the manufacture of a tubular side. It consists of the following elements.

Frame

Can be used as a thin-walled stainless steel or copper pipe.

Important! The use of conventional pipes, plastic or aluminum is undesirable - an aggressive "cocktail" of chemical compounds can lead to the destruction of the pipe and impurities in the final product.

The use of heat-resistant laboratory glass is justified if there is a need for visual control over processes. Glass is difficult to process, very fragile, but absolutely not subject to chemical destruction.

The body is best made cranked - a composite of 2-3 parts. This will make cleaning easier, and will also allow you to achieve different results.

Connections

There are several ways to connect pipes.

  • plumbing thread. The simplest and cheapest method. With each assembly, the knee columns are “twisted” with tow or fum-tape. Minus - the bulkiness of the method
  • Butt couplings - "American". Flat flares are compressed by threaded nuts. The pipes are sealed with gaskets, they will have to be replaced with silicone ones - they are not damaged by an aggressive environment.
  • Clamp clamps. Pipes at the joints have extensions, which are wrapped around with cone clamps. The most convenient and quick connection. Popular, but harder to find on sale.

Netting for stuffing

So that the spiral prismatic packing does not spill out into the distillation cube, you need to make a restrictive mesh at the bottom of the side.

The main property of this mesh is that it should be thick and made of thin stainless steel wires. So the cross section of the pipe will not decrease.

The use of a plate with drilled holes as a limiter will significantly degrade the parameters of the column.

Work progress

We select the pieces of pipes we need. They should be the diameter we need - from 24 to 60 mm. The productivity of the apparatus and the quality of the outgoing products depend on the diameter.

Cut pipes to size.

Important! The ends must be even, an oblique cut can lead to an inclination of the device, which will affect the quality of the entire system.

Solder with tin solder or weld connectors. It is better to use clamps - they are more reliable.

We make a grid-limiter for SPN (spiral-prismatic nozzle). We need a piece of pipe and a mandrel, 1-2 mm in diameter. thinner. We insert a mesh into the pipe, press it with a mandrel - we get a cylinder from the mesh.

The tsarga is going from bottom to top along the knees:

  • A limiter is placed for the nozzle, the first knee is attached to the cube.
  • The nozzle is filled up, after which the next knee is installed.
  • After using the tsarga, be sure to wash it with caustic soda and a brush.

Warming

Depending on the technology used, the tsarga needs to be insulated.

If normal distillation takes place, the lining is not needed to be insulated. It will be difficult to improve the result during rectification without insulation.

As a heater, you can use sanitary couplings made of foamed polyethylene, trays made of expanded polystyrene. You can fasten with disposable clamps or wire.

Watch a video in which an experienced moonshiner tells how to properly insulate a drawer:

Place of the device in the distiller

Moonshine stills are of various types. The drawer is not required to obtain raw alcohol, a steamer and a cooler are enough.

Reference! To obtain noble distillates or pure alcohol, a distillation column is indispensable. In this case, sampling units, coolers, bypass valves, temperature and pressure sensors are attached to the drawer.

The tsarga is not just a pipe. The main processes take place in it - the separation of alcohol vapors into fractions, as well as heat and mass transfer - the basis for obtaining high-quality alcoholic beverages at home.

People involved in moonshine are aware of the release of fusel oils (a by-product of the distillation of mash, a viscous liquid with a pungent odor) during the distillation of mash.
Various absorbers are used to reduce the amount of oil release and a cleaner distillation of the mash. Let's define such a strange term as absorption - this is the transfer of components (atoms) of a gas mixture into the volume of the condensed phase in contact with it. And the absorber is an element (filler) of the apparatus, on the surface of which the absorption process takes place. It should be noted that during the process, selective absorption of one or more components from the gas mixture by liquid absorbers occurs.
There are two types of nozzles: random (we just put them in the drawer, due to their small size) and regular (placed in the equipment in a special way)
In the role of absorbers in home brewing, the following are used: RPN Panchenkov nozzle, Selivanov nozzle (or spiral prismatic nozzle), Rashig rings.
The use of nozzles allows us to achieve a high distillation result and thus reduces the cleaning time.
Let's consider them in more detail separately.

And the first thing we start with is quite popular - On-load tap-changer Panchenkov nozzle, is a wire nozzle. It is used in tsargo-type distillers to improve purification, alcohol vapor is filtered through a nozzle, while depositing fusel oils and impurities from the mash on the grid.
The undoubted advantage of this nozzle is the possibility of its regulation in the side, i.e. we can roll it up to the density we need, and take it out of the apparatus for cleaning precipitated fusel oils.
The nozzle is made of food stainless steel.
You can buy a Panchenkov nozzle on our website

Next comes Selivanov nozzle, which is a spiral prism (made of wire materials). Designed to install a distillation column in the tsarga, it acts as a contact device. Usually nozzles of this type are made of copper and stainless steel. The nozzle is reusable and can serve as a filler for any tsarga.

And the last of the stated nozzles in this discussion is Raschig rings. This nozzle belongs to the regular type of nozzles. It has a cylindrical shape with a thin wall, and the outer diameter is equal to the height of the ring. Size range: from 25 mm to 150 mm. Most often, rings made of ceramics are used (a variation of porcelain is possible), carbon-graphite ones are found, and less often steel ones.

A small remark - nozzles. used to clean moonshine during the distillation process are not the know-how of recent years. They have been used in the chemical and petroleum industries for quite a long time (panel nozzles are another type), having proven themselves in this direction only from the best side. Therefore, relying on proven cleaning methods, the nozzles gradually entered the moonshine industry.