Concept, milestones of development and features of operation of the mash column. Technical features of the national distiller History of the appearance of the mash column

POTSTILL operating mode
“BK” (“BRK”) is designed to operate in three modes: as a simple distiller (Pot Still mode), as a mash column (BC) and as a distillation column (RC).
Pot Still is an option with a minimum height of the device. During the first distillation, vapor from the cube in which the mash is located rises up the reflux condenser (it is not connected or disconnected) and enters refrigerator where they are cooled. The vapors fill the refrigerator chamber, in which water moves towards them along a tubular coil.
In the refrigerator they condense and flow as a liquid through a hose into a receiving container. After the first distillation of the mash, a distillate is obtained, which is called raw alcohol with a strength (40-50%). It is not advisable to drink the resulting product, as it contains many harmful impurities. It is necessary to distill it again, that is, to perform fractional distillation. We select the tilt angle of the refrigerator depending on the distance to the receiving container. The refrigerator should face down.
IMPORTANT! We supply water for cooling when the temperature in the cube reaches 60-70 °C (according to the thermometer in the cube).

Operating mode "MAINE COLUMN"
For distillation, you can use both mash and raw alcohol. To begin, dilute the raw alcohol obtained after the first distillation to 35% -40%. Fill the cube no more than 2/3 of its volume and install the apparatus on the cube. Between the cube and the mini-reflux condenser, install a reinforcing frame filled with a regular wire nozzle (RPN). Connect the cooling water hose to the cold water main. Direct the drainage from the main refrigerator and the mini-reflux condenser into the sink. Lower the extraction hose finished product into a receiving container of sufficient volume.
The sampling hose MUST reach the collection container. The container must be of sufficient size (for example, a regular 3 liter jar).
DO NOT ALLOW overflow by changing containers in a timely manner. Turn on the heater to maximum power. Gradually open the needle valve so that cold water flows from the water supply into the mini-reflux condenser through the fitting. When the temperature in the cube reaches 60-70 °C, open the tap with cold water NOT AT FULL POWER. The stream flowing from the hose (red) from the main refrigerator should be approximately the thickness of a match and have a temperature of about -40-50°C (slightly hot to the touch). If you notice that steam is coming from the communication tube with the atmosphere, increase the pressure of cold water. If you notice that product selection does not occur, reduce the water supply to the mini-reflux condenser using a needle tap until the desired product selection rate appears.

We look at the thermometer in the column. The temperature there will gradually drop. After about 5-10 minutes it usually stabilizes to 79.3 - 80.5 °C. The water supply to the mini-reflux condenser is fully open. All product flows back into the cube through the on-load tap-changer nozzle (no selection occurs). We let the column work in this mode for about 10 - 20 minutes (working in this mode is called “working for yourself” - the selection is closed), then we begin to select the heads.
Selection of "heads".
“Heads” are acetones, aldehydes and other low-boiling toxic substances. To prevent them from getting into the drinkable part of the finished product, re-distillation must be fractional, that is, separate. Turn on the heater to maximum power. Turn on the water when the temperature in the cube reaches 60 - 70°C and monitor it. The contents of the cube will begin to boil and the temperature on digital thermometers will begin to rise. At approximately 75°C the first drops will begin to appear in the product extraction hose. It is necessary to reduce (adjust) the power of the heating device and the water pressure in the mini-reflux condenser (using a needle tap) so that the withdrawal rate is 1 - 2 drops per second. By volume, the “heads” should be approximately 10% of the amount of absolute alcohol (AS) in the cube. Or 50ml with 1 kg of sugar
Example 1: A cube is filled with 10 liters of raw alcohol with a strength of 40%, therefore, we consider 4 liters of AC (absolute alcohol).
That is, we must select dropwise 10% of 4 liters = 400 ml of heads.
Example 2: 6 kg of sugar is poured into the mash.
6 kg*50 ml=350 ml should be taken drop by drop.

Selection of the "body".
The body is the drinkable part of the final product with a high alcohol content of 60-93%. After completing the selection of heads, change the receiving container. Increase the heating power of the cube. When re-distilled at maximum power, the device can produce distillate up to 8 l/hour. We would recommend driving at medium speed (heating about 2 kW). The pressure of cold water should also not be high. Complete the “body” selection process when the thermometer in the cube shows 93-94°C.
The yield of the solid is approximately 40% of the poured volume of raw alcohol, depending on the strength obtained (the stronger the product, the smaller the resulting solid volume). Next, dilute the resulting distillate, the strength of which can reach 93%, with softened water to the required strength. By the way, using a needle tap and heating the cube, you can either reduce or increase the strength of the distillate at the outlet. The skills to manage this operation will come after several distillations. By opening the needle tap, we increase the water supply to the mini-reflux condenser (we reduce the selection and the strength increases).

Selection of "tails".
“Tails” are fusel oils. After selecting the body, according to your desire, the distillation can be completed, or you can change the receiving container and continue it until the temperature in the cube is 98-99°C. The resulting product is called "tails".


Operation in distillation column (RC) mode.
When rectifying raw alcohol, alcohol vapors from the still rise through the drawers into the main refrigerator. Pour raw alcohol into the cube. A digital thermometer is inserted into the cube and into the lower drawer. The water hoses are not connected to the mini-reflux condenser. A silicone hose with a Hoffmann clamp is connected to the tube of the liquid sampling unit (the silicone hose must reach the receiving container). Cold water is supplied to the main refrigerator (dephlegmator) through a blue hose. The hot water is discharged from the top of the refrigerator through the red hose into the drain. In the main refrigerator, the vapors condense and the condensate flows down into the liquid selection unit and to the tube through which the reflux is returned back to the drawers. Re-evaporation occurs at the SPN nozzle, due to which the product is cleaned and strengthened. The resulting product is 96.6% alcohol. Using a Hoffmann clamp, we can regulate the speed of product selection from drop by drop (head selection) to maximum. Thus, we can regulate the strength of the product (more opening of the Hoffmann clamp (with a needle tap) - less strength of the product and vice versa). We can regulate the so-called reflux ratio - this is the ratio of the product taken to the product returned to the drawer. To reduce the overall height of the structure, the main refrigerator can be tilted. The tilt angle of the refrigerator should be positive 15-25 degrees (that is, it should look up).

Rectification.
To begin, dilute the raw alcohol obtained after the first distillation to 40%. Fill the cube no more than 2/3 of its volume. Between the cube and the mini-reflux condenser, install reinforcing frames filled with a Selivanenko spiral prismatic nozzle (SPN). For the purest possible product, the recommended drawer height is 150 cm. Close the Hoffmann clamp (needle tap) on the silicone hose placed on the liquid sampling fitting. The silicone extraction hose MUST reach the collection container. The container must be of sufficient size (for example, a regular 3L jar). DO NOT ALLOW overflow by changing containers in a timely manner. Turn on the heater to maximum power. When the temperature in the cube reaches 60-70 °C, open the cold water tap NOT AT FULL power. Reduce the heat of the cube. The stream flowing from the hose (red) from the main refrigerator should be approximately the thickness of a match and have a temperature of about -40-50 °C (slightly hot to the touch). If you notice that steam is coming from the communication tube with the atmosphere, increase the pressure of cold water.
Regime stabilization (working for yourself).
We look at the thermometer in the drawer. The temperature there will gradually drop. After about 5-10 minutes it stabilizes, usually 78.3 - 78.5 °C. We let the column work in this mode for about 30 - 40 minutes (working in this mode is called “working for yourself” - the selection is closed). Then we start selecting the heads. Selection of "heads". “Heads” are acetones, aldehydes and other low-boiling toxic substances. To prevent them from getting into the drinkable part of the finished product, re-distillation must be fractional, that is, separate.
IMPORTANT!! DO NOT leave the device for a long time.
It is necessary to periodically check its operation!!
Turn on the heater to maximum power. Turn on the water when the temperature in the cube reaches 60 - 70°C and monitor it. The contents of the cube will begin to boil and the temperature on digital thermometers will begin to rise. At approximately 75°C the first drops will begin to appear in the product extraction hose. It is necessary to reduce (adjust) the power of the heating device so that the withdrawal rate is 1 - 2 drops per second. By volume, the “heads” should be approximately 10% of the amount of absolute alcohol (AS) in the cube.
Example 1: 10 liters of raw alcohol with a strength of 40% is poured into a cube, therefore, we consider 4 liters of AC (absolute alcohol).
That is, we must select dropwise 10% of 4 liters = 400 ml of heads.

Body selection.
This is the drinkable part of the final product with a high alcohol content of 95 - 96.6%. After selecting the “head”, change the receiving container. Increase the heating power of the cube. During rectification, the device can dispense a product up to 1.1 litres/hour (on drawers Ø50 mm).
But we would recommend driving at an average speed of 0.8 l/h (with a heating of about 1.5 kW).
The pressure of cold water should also not be high. Cold water consumption 30 - 60 lit/h. The water coming out of the red hose should have a temperature of 50 - 60°C. Complete the body selection process when the thermometer in the cube shows 93-94°C. The alcohol withdrawal rate should be 0.8 - 1.1 l/h (depending on the diameter and height of your drawers).
We regulate the selection speed using a Hoffmann clamp (needle tap) and heating the cube. 0.8 l/h is the optimal speed of product (alcohol) selection. The yield of the solid is approximately 40% of the poured volume of raw alcohol, depending on the strength obtained (the stronger the product, the smaller the resulting solid volume). Next, dilute the resulting product, the strength of which can reach 96.6%, with softened water to the required strength. By the way, by using a Hoffmann clamp and heating the cube, you can both reduce and increase the strength of the product at the outlet. By opening the Hoffmann clamp, we increase the rate of product release as its strength decreases. The skills to manage this operation will come after several distillations. The strength of pure alcohol should be 96.6% at a product temperature of +20 °C. Selection of "tails".
After selecting the body, according to your desire, the distillation can be completed, or you can change the receiving container and continue it until the temperature in the cube is 98-99°C.
The resulting product is called "tails".
After completing all processes, turn off the heating device and turn off the cold water supply. Wait until the apparatus has cooled down and disconnect the apparatus from the cube, drain the still residue, observing safety precautions. There is a hot liquid inside with a pungent odor (do not allow it to enter the respiratory tract). After draining the liquid, rinse the cube.

Technical features of the popular distiller

The market for moonshine brewing machines includes models ranging from very inexpensive semi-handicraft machines to almost professional home distilleries. It all depends on the level of the moonshiner, the desired range of drinks produced and the amount that the distiller is willing to spend on equipment. The moonshine still "National Distiller" from the company "Rectify" is a very budget model.

Technical features

The “National Distiller” moonshine still is a budget version of a film mash column. Another name is BK-51 (bar column 51 mm). It has a direct-flow reflux condenser with a jacket cooler. One of the features is the thermometer sleeve, which is located at the outlet of the reflux condenser.

If you use an additional drawer, according to the manufacturers, you can obtain a pervach with a strength of up to 96 degrees. With direct distillation, it is capable of producing up to eight liters of moonshine per hour, but if a product of greater strength and higher purification is required, then the productivity is much lower - up to two liters at 80 degrees and up to one and a half liters at 96 degrees of drink strength.

Only the distiller itself is available for sale from the manufacturer, but on some sites you can order it complete with alembic for twenty liters. The cost of a distiller ranges from four and a half to five thousand rubles. However, the kit does not include drawers to increase the strength of the product. They can be purchased separately from the same manufacturer. In order to assemble a complete alcohol mashine, you will have to spend an additional two to four thousand. So the moonshine still “National Distiller” will not be so cheap.

Consumer Opinion

Although the Rectify company, which is the manufacturer of this equipment, positions its moonshine still as budget, in fact it costs a rather impressive amount. The kit includes only the distiller itself and a silicone tube; all other components must be purchased separately. Even if you purchase the “National Distiller” complete with a still, the attachment to the still is sold separately. As a result, you will have to spend at least nine thousand rubles in order to get at least 80% moonshine.

At the same time, the apparatus does not contain such devices as a steam steamer or a bubbler. Accordingly, this machine can only produce drinks with the aroma of the original raw materials. It will not be possible to produce noble and exclusive drinks like cognac or whiskey using this equipment. For these purposes, you can purchase a gin basket from this manufacturer, which costs from three thousand rubles.

The device itself works properly, there are no complaints about its functioning. However appearance The device leaves much to be desired. The seams are quite roughly welded, and the device as a whole looks rather sloppy and unpresentable. In many reviews there are complaints about the quality of the drawer, which does not last long.

In light of all of the above, the question arises - why spend at least ten thousand rubles on a moonshine still that is not capable of producing anything other than ordinary moonshine or alcohol, and even with dubious workmanship. For the same money you can buy a quite decent distiller with a distillation column and other additional accessories, which will not only produce many different drinks, but will also have a presentable appearance and can serve as a gift. Despite the manufacturers’ claims, this device is not that budget-friendly; the low price of the distiller itself is more of a ploy to attract a buyer, since to assemble a full-fledged device you will need to spend two to three times the amount.

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 an understanding of the 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. Distillation column(RK) copes with these shortcomings, but has its own problems: expensive equipment, after rectification there is no smell of the original raw material left in the drink, and you still need a distiller 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 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 scheme with 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 significantly better than moonshine after fractional distillation in a conventional apparatus.

The euphoria can be explained by the fact that the high strength masks the unpleasant odor of the 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 reflux condenser is enough for all the intermediate harmful impurities accumulated in the pipe to immediately 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 in 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 the “heads” in the selection zone in large quantities due to the practically absent retention 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 fusel oils at least 1-2 thousand mg per liter, more often – much more. 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, the BC, in the classic form of a 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

Newcomers often complain that despite all their efforts, they mash column the result is pure alcohol, 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 it is underestimated, then the output will no longer be a good distillate, but poorly purified alcohol, which is quite suitable for a barrel - the 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.