Comparison of columns with inclined and vertical dephlegmator. How to improve the composition of moonshine or what is a dephlegmator for? Which is better, how to do it yourself. How to do it at home

It is no secret that the most important stage in the process of making moonshine is its cleaning. It also presents the greatest difficulty. And before preparing this drink for the first time, everyone who decides to try himself in this business has several questions - how to carry out this process and make it as effective as possible, and at the end get a high-quality product without unnecessary impurities. An important aspect when choosing a cleaning method is often its cheapness and ease of use.

There are many different "notions" from folk craftsmen. Sometimes, people use whatever comes to hand to improve the quality of their drinks. Such improvised means are, for example. But among them, a dephlegmator for a moonshine still stands alone.

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How to understand that we have a dephlegmator

So, in case of some confusion that has a habit of reigning on the Internet, let's immediately clarify some details. A dephlegmator, a dry steam bath, a wet steam bath, a steam bath - all of these are not the same thing. There is no fundamental difference in the way they work, they differ in the complexity of the design. In some versions of the dephlegmator, several dry boxes are its elements. This article is about a dephlegmator, but for a better experience compare device of a moonshine still with a steamer:

• Cap.
• Thermometer.
• Connecting tube.
• Refrigerator.
• Drain pipe.
• Receiving Flask.

And not the most cunningly invented dephlegmator:

• The first greenhouse.
• The second sucker.
• Drain connection.
• Refrigerator.
• Drain pipe.
• Water supply tube.

As you can see, there is a difference. Not too significant, but it plays a certain role in the choice of a purifier. So, a dephlegmator is one of the parts of a moonshine still. It looks like a tank for cooling vapors, some of which are boiled over and sent back to the coil. If you have secured the dephlegmator correctly, it will be attached to it and the distillation cube with small diameter tubes.

If we compare the preparation of moonshine with a complex surgical operation, then the high content of fusel oils is inevitable death. The dephlegmator here plays the role of a defibrillator and helps to save the life of the moonshine. At the same time, the dephlegmator is an optional part of the moonshine still. By helping to minimize the amount of various impurities, such as fusel oils, it improves the quality of the resulting drink and increases its final strength. So whether to use it or not is up to you. But we would recommend doing this.

First of all, you need to understand the basic principles of its work. Nothing complicated here. You only need to know that the boiling point of harmful impurities, most of which are fusel oils, is slightly lower than that of ethyl alcohol. And then the rest of the work of the moonshine still with the use of a dephlegmator becomes clear. The main advantages of using it are as follows:

• harmful impurities enter it first, immediately condense, but do not boil, because all thermal energy is spent on the evaporation of alcohol - this method is much more perfect than, with which it is better to strengthen the dephlegmator method, and not apply separately;
• after this distillation, the initial mass of hazardous substances does not enter the final product due to the fact that the reflux condenser does not allow them to spill out of its walls;
• the amount of alcohol in the brewed moonshine increases due to the return of bad residues to the distillation cube;
• increasing the strength of the resulting drink and the possibility of improving its taste due to various fruit additives;
• reduction of unpleasant taste and odor due to the removal of fusel oils from the distillate.

Imagine something very unpleasant in appearance and having a repulsive smell. Something should come out that, in terms of the damage done to your sense of smell, is not a drop inferior to the resulting light brown slurry with a pungent fetid odor. These are the very "waste" substances. Their output quantity, as well as the quantity of the drink itself, depends on what raw materials and the design of the apparatus you used. The design, which assumes the presence of a dephlegmator, reduces the amount of this waste to the very minimum values \u200b\u200b(on average, with traditional fermentation, they account for 300-400 ml for every 7 liters of the final moonshine with a strength of 45 degrees).

What are reflux condensers?

Moonshine has a huge number of different types of reflux condensers. They differ from each other in very different ways, only the principle of operation remains unchanged. All the rest of the function changes, varies and is configurable: design, number of additional elements, method of application, shapes, dimensions. It all depends on what characteristics the manufacturer wants to see in his device as a result.

Even the material from which the dephlegmator can be made varies. Glass, stainless steel tubes (or, “in Russian” speaking, “stainless steel”), copper or even titanium. Although, we note that the last two options are less common due to their predatory inclinations for the pocket of buyers. And there is not much difference in this case. The most common models of reflux condensers are:

• Dimroth.
• Le Chatelier.
• Bunsen.
• Cylindrical with a nozzle.

All of the listed types of reflux condensers greatly contribute to the correct process of distillation of moonshine, which implies a qualitative improvement in the final product. The principle of operation is the same for all of them. Most of the differences are related to the applied design methods of moonshine stills. Moonshine makers prefer the Dimroth reflux condenser, a smaller copy of the rectification column. A distillation column is a rather capricious type of dephlegmator in manufacturing, requiring some skills in needlework, but its manufacture does not take so much time and effort as a long search for the necessary materials.

Alchemists could not make a philosopher's stone, but you can make a reflux condenser with your own hands

Plus, you can do this in several ways. Each of them will not take you any long time. So, here are the simplest ones:

Making with your own hands from an ordinary thermos dephlegmator Dimroth.

Yes, you heard right. Now you can boast that you know how to use a thermos not only for carrying hot drinks in it, but also for making a dephlegmator with your own hands. You will need minimal knowledge of how to solder, grind seams, and drill a few holes. The sequence of actions is as follows:

1. thoroughly clean the bottom of the selected thermos. The size is adjusted according to your needs;
2. we take out the inner flask and grind each detected seam so that a visible gap appears;
3. we mount a tube to the removed flask, it will provide ventilation;
4. we fix a test tube at the bottom of the resulting vessel;
5. solder the intake assembly to the neck;
6. we prepare the holes in the sleeve and fix the tubes in them.

Do-it-yourself dephlegmator made of "stainless steel".

All that we need from the category of something that is not so easy to find at home right away is a piece of stainless steel pipe. But, if you live in an apartment, it is easier to buy a "stainless steel" somewhere - it will take an order of magnitude less time. Remember that the size of the distillation still increases in proportion to the size of the settling tank. We also need a skill from the frequently encountered category "I would like to learn this" - locksmith. The process is somewhat laborious, since it requires at least a little experience in working with the welding machine, and proceeds in a similar way to the previous image. The only difference is that it will be necessary to solder parts of the structure together.

Least energy consuming a method to make a dephlegmator for a moonshine still with your own hands. Everything you need can be easily counted on the fingers of one hand. Let's check:

• a jar with a recommended volume of at least 750 ml, although even here its size is determined by the personal needs of each;
• nuts;
• fittings;
• glue.

Remember that all components must be able to withstand the temperature applied during the distillation of the moonshine. Take a moment to clarify this point. Save yourself a lot of nerves. The procedure for creating a reflux condenser is as follows:

1. a cover is taken, marks are made on it in those places where the fittings are mounted;
2. considering their size, we mark the outlines;
3. cut out the holes;
4. we apply glue along their edges;
5. fix the nuts.

This article clearly reveals the meaning of such a useful element of a moonshine still as a dephlegmator. Its design and principle of operation are analyzed in detail, which ultimately makes it possible to discover many ways of its independent production. In addition, the most popular ones have been described along with other information that will be absolutely useful to anyone interested in home brewing.

In this article, we told you how to make a device for making pure moonshine with your own hands. It is possible that one day we will publish a practical guide to creating a philosopher's stone. In the meantime, it is carefully kept secret, you can follow our new articles.

All dephlegmators used in home brewing can be conditionally divided into two large classes: film and all the rest. The fundamental difference lies in the fact that in the classical film construction there are no additional elements: reflux condenses on the walls of the vertical tube and re-evaporates from it. The main advantage is the simplicity of the design, which can be made by hand, the main disadvantage is the interaction of the phlegm with the peripheral region of the steam flow, and not with the central one.

“All the rest” are reflux condensers, into the inner cavity of which various elements are introduced: fillers with a developed surface area (plates, glass beads, etc.) made of inert material. Due to them, the efficiency of interaction of steam with reflux increases, and the overall dimensions of the device are reduced. We list only some types of reflux condensers:

• Le Chatelier;
• Bunsen;
• christmas tree;
• packed;
• Dimroth, etc.

According to the ratio of product quality / dimensions / ease of manufacture / convenience of adjusting the operating mode - practicality, in a word, preference is given to the Dimroth design.

Some methods of making the simplest reflux condensers

1. Upgraded dryhouse... Strictly speaking, even a self-made primitive is a glass jar, but it still performs some functions of a dephlegmator. But only a few, and only if we say "very strictly". In order for it to become an elementary uncontrolled dephlegmator, its design and placement must be changed. This is done easily and with your own hands.

• At the top, only one outlet remains.
• The body is made of thin metal.
• A metal tube is soldered into the bottom, which is then connected to the lid of the distillation cube.
• This whole structure is installed, in contrast to the classic dry pot, not from the side, but above the distillation tank with the initial mixture.

As a result, the reflux condensed on the walls of the casing flows down the tube back to the tank, meets with the newly formed steam, partially re-evaporates and goes for sampling. The strength and purity of the product are insignificant, but they increase.

1. Do-it-yourself dephlegmator from two tubes - the simplest film. From the outside of the large tube, two pipes are welded into the walls at the ends. A tube of a smaller diameter is inserted into a larger one. The ends are welded to form a cavity (shirt) between them. The whole structure is connected to an opening in the alembic lid. Cold water circulates in the resulting shirt.

Steam from the container rises inside the tube, condenses on its cold walls and flows down them back into the container. When interacting with the counter flow of steam, the reflux is repeatedly re-evaporated and divided into fractions. By adjusting the intensity of cooling, all components are sequentially separated from the feedstock, starting with the low-temperature component.

1. Dimroth's dephlegmator... Two tubes. One of them serves as a body, from the second the spiral is rolled up so that it enters the body with a small gap. The structure is installed on the lid of the distillation tank, water circulates through a spiral tube. In contrast to the film construction, here the condensation and re-evaporation of reflux occurs on the surface of the spiral.

We will separately consider a reflux condenser, which, if it is made available at home with our own hands, gives a very good result for the final product.

Dephlegmator from a metal thermos

The basis of this design will be a thermos with a volume of 0.5-1 liters. Let's get started.

1. We disassemble the thermos, that is, remove the bottom so as not to damage the flask itself. To do this, we clean the platform on the bottom and solder a metal bracket to it. We fasten a wire or a steel cable to the bracket. We securely fix the other end of the wire and strongly pull the thermos towards ourselves. The bottom should come off the thermos flask. To facilitate the process, you can preheat it with a burner.
2. Next, it is necessary to grind off the rib along which the partition is connected to the outer bulb in such a way that an almost indistinguishable uniform gap appears around the entire circumference. To do this, it is best to use a drill with a nozzle or, if there is access, an emery machine. After that, the bulkhead of the thermos is easily separated from the outer flask.
3. In order to remove the inside of the flask, it is also necessary to carefully grind off the rib on the neck of the thermos. As a result, the inner part can be easily removed from the outer part.
4. Drill a hole in the bottom of the inner flask, insert a tube into it for communication with the atmosphere and tin the junction.
5. In the wall of the outer flask, at the top and bottom, we cut and solder two nozzles to organize the circulation of cooling water. In this case, it is necessary to ensure that the ends of these tubes protrude into the inside of the flask at a distance less than the size of the gap between the flasks.
6. We assemble the flask: carefully solder the gaps made earlier, drill a hole in the bottom and the partition under the tube and put them in place.

In principle, our do-it-yourself reflux condenser, as far as the thermos itself is concerned, is ready. Its working position on the moonshine still with the neck down. But it does not yet have the most important node, because of which everything was started: the node for selecting the finished product.

Selection node

It will be connected to the neck of the thermos. Its design and position in the moonshine still is shown schematically in the figure below.

Dephlegmator working scheme

It is made from a piece of pipe with two adapters: the upper one for the neck of the thermos, the lower one for the tube connecting the reflux condenser with the distillation still. A wide washer with a low rim (8-10 mm) is welded inside the tube along the edge of the central hole. If you have the skill, then you can handle the installation of the washer with your own hands, if not, then contact the workshop. Just above the bottom, formed along the wall of the bowl pipe, a hole is drilled for a branch pipe through which the finished product will come out.

It is not shown in the diagram, but a thermometer or a temperature sensor is also needed to accurately adjust the operating mode of the device. To install it, just above the top edge of the washer, drill a hole for the thermometer sleeve in the pipe wall.

So, the dephlegmator is assembled. It can be connected through a tube (50-80 cm long) to the lid of the distillation vessel and start getting the finished product. But if we want to get really high-quality alcohol, then we should think about replacing the tube with a full-fledged rectification column.

The dephlegmator is part of the moonshine still, which ensures the production of alcohol, in quality closer to —vodka — than to moonshine obtained without it, which is no less important for completeness of the picture, the distillation rate also increases.

The principle of operation is based on the rectification process - separation of a mixture of several liquid substances into separate components.

There are several schematic diagrams according to which units for rectification are manufactured. The simplest ones consist of several pipes welded together, the more complex ones have a cooling system, but any of them can be made in a domestic environment.

Description

—The device of a moonshine still — can vary from a very simple one, consisting of — a distillation cube — — a refrigerator — and — hoses — to a very complex one, close in structure to an industrial installation.

The dephlegmator belongs to additional unitsdesigned to improve the distillation process and the quality of the final product - moonshine.

Usually located directly above the distillation still and can be part of the “distillation column”.

The simplest design - film - consists of a vertical tube, more complex types have an increased condensation area, and are also complemented by a cooling system that enhances and controls the process of separating the liquid into components.

Appointment

The device ensures the course of the rectification process, which, in contrast to distillation, where the liquid simply condenses after evaporation, consists in multiple re-evaporation of the condensate and simultaneous gas-liquid exchange between it and the rising vapor.

After which the condensate flows into the distillation cube and evaporates again, the process continues cyclically. Due to this, alcohol is separated from unnecessary impurities much more efficiently.

Thus, a reflux condenser in a moonshine still is needed for the rectification process, which significantly improves the taste and aroma properties of moonshine, its strength and purity, which cannot be achieved by distillation alone.

The device and principles of operation of a dephlegmator in a moonshine still

To ensure minimal rectification above the distillation still, it is sufficient to install a high tube with a sealed top and a steam outlet near it.

The dephlegmator device for a moonshine still of this type is called film. The other type includes units equipped with additional surfaces, for example, internal fins that increase the condensation area, as well as water cooling to control the rectification process.

In this case, the design necessarily contains a "thermometer", according to the indications of which the water supply is regulated.

The performance of moonshine stills equipped with a rectification unit with a cooling system is much higher, and among all the variants of this type of construction, the “Dimroth model” stands out.

Its relative simplicity and efficiency, not much inferior to a full-fledged rectification column, puts it in first place in home brewing.

The essence of the rectification process

Braga is a solution of many separate substances: alcohol, water, fusel oils and other impurities. Each of them has a different boiling and evaporation point.

The dephlegmator for a moonshine still is designed in such a way that steam, once it gets into it, is cooled to a certain temperature - 78 C degrees, ideally, in such conditions evaporated impurities and fusel oils, which have a higher boiling point, cannot maintain a gaseous state, as a result they begin to condense on the walls.

And the purified steam, now consisting mainly of alcohol and water, flows into the outlet at the top further along the system.

Did you know? Often a reflux condenser is confused with a “dry steam”, which, although it performs some of its tasks, does not provide complete rectification due to the absence of cyclic re-evaporation. In addition, the dry steamer performs a protective function in the event of a mash splash.

How to do it yourself

Film with cooling

An improved version of the simplest design. It consists of two pipes: a smaller and a larger diameter, the first is inserted and welded inside the second, in the walls of which two holes are made - one at the bottom and one at the top for water supply and outlet, respectively.

The structure is installed above the alembic. Vapors from the cube enter the central cavity and, partially condensing on the cooled walls, flow back, where they evaporate again.

The outer part is a water jacket, inside of which water circulates, providing cooling, and the intensity of its supply makes it possible to control the rectification process. You can make such a moonshine still with a reflux condenser using a simple drawing.

Dimroth's model

The structure consists of two tubes, the first acts as a body, inside which there is steam from a cube.

From the second, a spiral is rolled up, along which water will circulate, while there should be a gap between the spiral and the body.

The unit is installed immediately above the alembic. This very simple design is more efficient than the film design, in part because the condensation surface is in the center rather than at the edge of the device.

Small summary

Having studied all the details and understanding how a dephlegmator works in a moonshine still, we can confidently say that the benefits of using it are incomparable with the resources required to create it. The Dimroth refrigerator deserves special attention, combining high efficiency with a simple design. Rectified moonshine is a product of a completely different level, and this applies both to the taste and aroma of the drink, and to the content of fusel oils and other impurities.

The most common type of heat exchanger in the industry is a shell and tube. The variant of its design depends on the tasks facing the users. The shell-and-tube does not have to be multi-tube - a conventional jacket-type reflux condenser, direct-flow (a) or counter-flow (b) cooler of the "pipe-in-pipe" type are also shell-and-tube pipes.

One-way heat exchangers with cross-flow heat transfer fluids (c) are also used. But the most effective and often used for multi-tube heat exchangers is the multi-pass cross-flow scheme (d).

With this scheme, one flow of liquid or vapor moves through the pipes, and the second coolant moves towards it in a zigzag manner, repeatedly crossing the pipes. It is a hybrid of counterflow and crossover options, which allows the heat exchanger to be as compact and efficient as possible.

The principle of operation of shell and tube heat exchangers and their scope

In home brewing, multi-pass cross-flow refrigerators are usually called shell-and-tube coolers (KHT), and their one-pipe version is called a counter- or direct-flow refrigerator. Accordingly, when using these structures as dephlegmators - shell-and-tube and jacket dephlegmators.

In home moonshine stills, beer and rectification columns, steam is supplied to these heat exchangers through internal pipes, and cooling water is supplied to the casing. Any industrial designer-heating engineer would be outraged, since it is in the pipes that a high speed of the coolant can be created, significantly increasing the heat transfer and efficiency of the installation. However, distillers have their own goals and do not always need high efficiency.

For example, in reflux condensers for steam columns, on the contrary, it is required to soften the temperature gradient, spread the condensation zone as much as possible in height, and, having condensed the necessary part of the steam, prevent overcooling of the reflux. Moreover, and precisely regulate this process. Quite different criteria come to the fore.

Among the refrigerators used in home brewing, the most widespread are coils, direct-flow and shell-and-tube pipes. Each of them has its own scope of use.

For devices with low (up to 1.5-2 l / h) capacity, the most rational use of small flow-through coils. In the absence of running water, the coils also give odds to other options. The classic version is a coil in a bucket of water. If there is a water supply system and the capacity of the device is up to 6-8 l / h, then the direct-flow lines designed according to the principle of "pipe in pipe", but with a very small annular gap (about 1-1.5 mm), have an advantage. A wire is spirally wound onto the steam pipe with a step of 2-3 cm, which centers the steam pipe and lengthens the path of the cooling water. With heating powers up to 4-5 kW, this is the most economical option. The shell and tube, of course, can replace the straight-through, but the manufacturing cost and water consumption will be higher.

The shell and tube comes to the fore with autonomous cooling systems, since it is completely undemanding to water pressure. As a rule, a conventional aquarium pump is sufficient for successful operation. In addition, with heating powers of 5-6 kW and above, a shell-and-tube refrigerator becomes practically no alternative, since the length of a once-through refrigerator for utilizing high capacities will be irrational.

For reflux condensers of mash columns, the situation is somewhat different. With small, up to 28-30 mm, diameters of columns, the most rational is a conventional shirting (basically the same shirting).

For diameters of 40-60 mm, the leader becomes This is a high-precision cooler with a clear power control and an absolute reluctance to air. Dimroth allows you to adjust the modes with the least hypothermia phlegm. When working with packed columns, due to its design, it makes it possible to center the reflux return, in the best way irrigating the packing.

The shell and tube comes to the fore with autonomous cooling systems. Reflux irrigation of the packing occurs not in the center of the column, but over the entire plane. This is less effective than Dimroth's, but perfectly acceptable. The water consumption in this mode for the shell and tube will be significantly higher than that of Dimroth.

If you need a condenser for a column with liquid withdrawal, then Dimroth is out of competition due to the accuracy of regulation and low subcooling of the reflux. The shell-and-tube is also used for these purposes, but the hypothermia of the phlegm is difficult to avoid and the water consumption will be higher.

The main reason for the popularity of shell and tube assemblies among manufacturers of household appliances is that they are more versatile in use, and their parts are easily unified. In addition, the use of shell-and-tube dephlegmators in apparatus of the "constructor" or "changeling" type is beyond competition.

Calculation of the parameters of the shell-and-tube dephlegmator

The calculation of the required heat exchange area can be performed using a simplified procedure.

1. Determine the heat transfer coefficient.

Calculation formulas:

R \u003d h / λ, (m2 K) / W;

Rs \u003d R1 + R2 + R3 + R4, (m2 K) / W;

K \u003d 1 / Rs, W / (m2 K).

2. Determine the average temperature difference between steam and cooling water.

Saturated alcohol vapor temperature Tp \u003d 78.15 ° C.

The maximum power from the reflux condenser is needed in the mode of operation of the column towards itself, which is accompanied by the maximum supply of water and its minimum outlet temperature. Therefore, we assume that the water temperature at the inlet to the shell and tube (15 - 20) is Т1 \u003d 20 ° C, at the outlet (25 - 40) - Т2 \u003d 30 ° C.

Tvx \u003d Tp - T1;

Thv \u003d TP - T2;

The average temperature (Tav) is calculated by the formula:

Tav \u003d (Tvx - Tvyh) / Ln (Tvkh / Tvyh).

That is, in our case, rounded:

Thv \u003d 48 ° C.

Tav \u003d (58 - 48) / Ln (58/48) \u003d 10 / Ln (1.21) \u003d 53 ° C.

3. Calculate the heat transfer area. Based on the known heat transfer coefficient (K) and the average temperature (Tav), we determine the required surface area for heat exchange (St) for the required thermal power (N), W.

St \u003d N / (Tav * K), m 2;

If, for example, we need to recycle 1800 W, then St \u003d 1800 / (53 * 1493) \u003d 0.0227 m 2, or 227 cm 2.

4. Geometric calculation. Let's decide on the minimum diameter of the tubes. In the dephlegmator, the phlegm goes towards the steam, therefore, it is necessary to observe the conditions for its free flowing into the nozzle without excessive hypothermia. If you make tubes of too small a diameter, you can provoke a flood or release of phlegm into the area above the dephlegmator and further into the selection, then you can simply forget about a good cleaning of impurities.

The minimum total cross-section of the tubes at a given power is calculated by the formula:

Ssection \u003d N * 750 / V, mm 2, where

N - power (kW);

750 - steam generation (cm 3 / s kW);

V is the steam velocity (m / s);

Ssection - the minimum cross-sectional area of \u200b\u200bthe tubes (mm 2)

When calculating column-type distillers, the heating power is selected based on the maximum steam velocity in the column of 1-2 m / s. It is believed that if the speed exceeds 3 m / s, then the steam will drive the reflux up the column and throw it into the selection.

If you need to dispose of in a 1.8 kW dephlegmator:

Ssection \u003d 1.8 * 750/3 \u003d 450 mm 2.

If you make a reflux condenser with 3 tubes, then the cross-sectional area of \u200b\u200bone tube is not less than 450/3 \u003d 150 mm 2, and the inner diameter is 13.8 mm. The nearest larger of the standard pipe sizes is 16 x 1 mm (inner diameter 14 mm).

With a known pipe diameter d (cm), we find their minimum required total length:

L \u003d St / (3.14 * d);

L \u003d 227 / (3.14 * 1.6) \u003d 45 cm.

If we make 3 tubes, then the length of the reflux condenser should be about 15 cm.

The length is adjusted taking into account that the distance between the partitions should be approximately equal to the inner radius of the body. If the number of partitions is even, then the pipes for supplying and draining water will be on opposite sides, and if odd, on one side of the dephlegmator.

An increase or decrease in the length of the pipes within the radius of the household columns will not create problems with the controllability or power of the dephlegmator, since it corresponds to the calculation errors and can be compensated for by further design solutions. You can consider options with 3, 5, 7 or more tubes, then choose the best one from your point of view.

Design features of a shell-and-tube heat exchanger

Partitions

The distance between the baffles is approximately equal to the radius of the body. The smaller this distance, the higher the flow rate and the less the possibility of stagnation zones.

Baffles direct the flow across the tubes, which significantly increases the efficiency and power of the heat exchanger. The baffles also prevent the tubes from bending under the influence of thermal loads and increase the rigidity of the shell and tube dephlegmator.

In the partitions, segments are cut out for the passage of water. The segments must be at least as large as the cross-sectional area of \u200b\u200bthe water supply pipes. Usually this value is about 25-30% of the area of \u200b\u200bthe partition. In any case, the segments must ensure the equality of the water velocity along the entire path of motion, both in the tube bundle and the gap between the bundle and the body.

For a dephlegmator, despite its small (150-200 mm) length, it makes sense to make several partitions. If their number is even, the fittings will be on opposite sides, if odd - on one side of the reflux condenser.

When installing transverse baffles, it is important to maintain as little clearance as possible between the body and the baffle.

Tubes

The wall thickness of the tubes does not really matter. The difference in heat transfer coefficient for wall thicknesses of 0.5 and 1.5 mm is negligible. In fact, the tubes are thermally transparent. The choice between copper and stainless steel, in terms of thermal conductivity, also makes no sense. When choosing, one must proceed from the operational or technological properties.

When marking the tube sheet, they are guided by the fact that the distances between the axes of the tubes must be the same. They are usually placed at the vertices and sides of a regular triangle or hexagon. According to these schemes, at the same step, it is possible to place the maximum number of tubes. The center tube most often becomes a problem if the distances between the tubes in the bundle are not the same.

The figure shows an example of the correct hole pattern.

For the convenience of welding, the distance between the tubes should not be less than 3 mm. To ensure the strength of the joints, the material of the tube sheet must be harder than the material of the pipes, and the gap between the sheet and the pipes must be no more than 1.5% of the pipe diameter.

When welding, the ends of the pipes should protrude above the grating at a distance equal to the wall thickness. In our examples - by 1 mm, this will allow you to make a high-quality seam by melting the pipe.

Calculation of parameters of a shell-and-tube cooler

The main difference between a shell-and-tube refrigerator and a reflux condenser is that the reflux in the refrigerator flows in the same direction as the steam, therefore, the reflux layer in the condensation zone increases from minimum to maximum more smoothly, and its average thickness is somewhat larger.

For calculations, we recommend setting the thickness equal to 0.8 mm. In a reflux condenser, the opposite is true - at first, a thick layer of phlegm that has merged from the entire surface meets steam and practically does not allow it to fully condense. Then, having overcome this barrier, the vapor enters the zone with a minimum, about 0.5 mm thick, reflux film. This is the thickness at the level of its dynamic retention; condensation occurs mainly in this zone.

Taking the average thickness of the reflux layer to be equal to 0.8 mm, for a specific example, we will consider the features of calculating the parameters of a shell-and-tube cooler using a simplified method.

The maximum power requirements for the refrigerator are made by the first distillation, for which the calculation is made. Useful heating power - 4.5 kW. Water temperature at the inlet - 20 ° C, at the outlet - 30 ° C, steam - 92 ° C.

Tvx \u003d 92 - 20 \u003d 72 ° C;

Thv \u003d 92 - 30 \u003d 62 ° C;

Tav \u003d (72 - 62) / Ln (72/62) \u003d 67 ° C.

Heat exchange area:

St \u003d 4500 / (67 * 855.6) \u003d 787 cm².

Minimum total cross-sectional area of \u200b\u200bpipes:

S section \u003d 4.5 * 750/10 \u003d 338 mm²;

We choose a 7-pipe refrigerator. Sectional area of \u200b\u200bone pipe: 338/7 \u003d 48 mm or internal diameter 8 mm. From the standard range of pipes, 10x1 mm (with an inner diameter of 8 mm) is suitable.

Attention! When calculating the length of the refrigerator, an outer diameter of 10 mm is needed.

Determine the length of the refrigerator tubes:

L \u003d 787 / 3.14 / 1 \u003d 250 cm, therefore, the length of one tube: 250/7 \u003d 36 cm.

We clarify the length: if the refrigerator body is made of a pipe with an inner diameter of 50 mm, then there should be 25 mm between the partitions.

36 / 2,5 = 14,4.

Therefore, it is possible to make 14 partitions and get water inlet-outlet pipes in different directions, or 15 partitions and pipes will look in one direction, the power will also increase slightly. We select 15 partitions and adjust the length of the tubes to 37.5 mm.

Drawings of shell-and-tube reflux condensers and refrigerators

Manufacturers are in no hurry to share their drawings of shell-and-tube heat exchangers, and home craftsmen do not really need them, but still some schemes are in the public domain.

Afterword

It should not be forgotten that all of the above is a theoretical calculation using a simplified method. Thermal calculations are much more complicated, but in the real household range of changes in heating power and other parameters, the method gives correct results.

In practice, the heat transfer coefficient may be different. For example, due to the increased roughness of the inner surface of the pipes, the phlegm layer will become higher than the calculated one, or the refrigerator will be located not vertically, but at an angle, which will change its characteristics. There are many options.

The calculation allows you to accurately determine the dimensions of the heat exchanger, check how the change in the diameter of the pipes will affect the characteristics, and reject all unusable or guaranteed worst options at no extra cost.

A dephlegmator for a moonshine still is a device that has several names, and there is still debate about its necessity. But, despite such active discussions, no one even thinks to beg for the merits of a dephlegmator.

Why you need a moonshine still is clear to everyone. Despite the fact that the structure has a primitive structure, it can be modernized. Modernization will help to significantly improve the quality of products: it will make the moonshine cleaner and get rid of unpleasant odors.

The location of the steamer in the moonshine still

A dephlegmator, or dry steam tank, is an integral part of the device, a kind of sump, in which harmful fusel oils settle during distillation. It is the fuzzy that spoils the quality of alcohol, it can cause severe intoxication.

Moonshine stills are different, for example, with and without a dry steamer, but this does not mean at all that the devices work in the same way. The structure of the device has a direct impact on the quality of the moonshine. If the apparatus does not have a refrigerator, a steam pot and a distillation still, then it is difficult to rank it among devices for the production of alcoholic beverages at home.

Each part of the unit performs specific functions. If we talk about a dephlegmator (dry steam room, sump), then it helps:

• Significantly improve the taste of alcohol, eliminate the unpleasant odor and even remove the aftertaste, affect the strength of the drink.
• Avoid getting the boiling mash into the container with the finished distillate. When the mash boils in the distillation still, a small amount of it in the form of a spray can get into the container with the finished alcohol - this event will not have the best effect on the quality of the product. You can pour the moonshine back into the cube and start processing it again, since the concentration of fusel oils is high in the wash.
• The peculiar device of the dephlegmator helps to divide the moonshine into fractions: to separate the “heads” from the “body” and select the “tails”, due to which the quality of the product will only benefit.
• Another dry greenhouse is used as a flavoring agent. Various components (lemon or orange peel, spices, spices and other substances) are put into it, which can give the drink a pleasant smell and taste.

It should be understood that some devices are equipped with several dry steam pipes. The presence of additional modules affects the quality of the moonshine. In some cases, reflux condensers work so efficiently that they can produce high strength alcohol at home.

Many people think that only a moonshine is equipped with a dry steamer, but a rectification column does not need such a device. In fact, this is not entirely true. The rectifier often has one or two settling tanks. It is these modules that help the device to produce raw alcohol with a strength of up to 96 degrees.

How the reflux condenser works:

1. Alcohol boils at a lower temperature than fusel oils and water.
2. When the vapors begin to evaporate, they pass through the dry chamber. Harmful fusel oils settle on the walls of the reflux condenser, as well as in the water contained in the sump. This blocks the ingress of harmful substances into the finished product.
3. Partially, alcohol vapors continue to move, they get into the refrigerator, pass along the coil and turn into a rather strong product.

At its core, a dephlegmator is a kind of filter that traps fusel oils, drops of home brew, various impurities, etc. It allows you to improve the taste of the product, increase its strength and provide the moonshine with high-quality moonshine.

What is the purpose of the second dry steamer in this case? The answer to this question is obvious: the second dry-pot, or dephlegmator, helps not only to clean the moonshine from the booze, but also to increase its strength. The design of the unit may have two or more dry steam rooms. One of them is used to add aroma to the drink, and the other cleans the moonshine from harmful impurities. The more dry hoppers in the unit, the better the alcohol it produces.

Designs with three dry steamers are used for the distillation of noble drinks such as whiskey, cognac and even rum.

The main advantages of the reflux condenser

Understanding how the dry steam tank works and why it is needed, it is worth noting that the device has several advantages. A moonshine still with a reflux condenser is a special device that has a number of positive characteristics. The presence of an additional module optimizes the operation of the device and helps:

1. Reduce the concentration of fusel oils in alcohol. If a reflux condenser is built into the distillation column, then it allows obtaining a highly purified alcohol. This product does not require re-distillation, it is of high quality. A moonshine still, or rectifier with a steamer, is a practical device. Compared to chemical cleaning methods, cleaning with a dephlegmator is more efficient.
2. Increase the strength of the drink. This is due to the fact that the phlegm returns back to the mash, which allows you to increase the strength of the drink.
3. Protect practically ready-to-drink alcohol from particles of boiling mash getting into it. This means that the device acts as a barrier element.
4. Give alcohol a pleasant smell and taste if aromatic substances are used in the pasture process.

But the main thing is that the dephlegmator simplifies the receipt of finished products, it allows you to make high quality moonshine without much effort, without carrying out the second or third distillation of the mash.

Do-it-yourself dephlegmator

It is not so difficult to make a dry steamer for a moonshine still with your own hands; you will need some knowledge of the details of the structure of the unit and the functions of the additional module.

If you study the drawing, you will notice that the reflux condenser is a kind of container that is used as a settling tank. The capacity has certain structural features, relying on them and you can make the module yourself. But if there are no skills in the design and creation of moonshine stills or its parts, then it is better to purchase the device in the store.

How to make a dry greenhouse yourself:

• To create a device, you need a glass jar with a screw cap. You can also take a jar with a sealed tin lid, which cannot be removed, but such a dry pot cannot be washed and cleaned of fusel oils and mash residues.
• Two fittings and two nuts, as well as materials for sealing the structure. You can use regular superglue or epoxy.
• And you will also need hoses and tools that will help you make two holes in the lid, it is advisable to take an awl.

When all the source materials are ready, you can start making the module yourself.

Algorithm of actions when working with materials:

1. Marking is applied to the metal cover in those places where the fittings will be located. Marking can be done using a marker, the main thing is not to be mistaken with the diameter.
2. When the markings are applied to the surface of the lid, you can make holes in the metal. This can be easily done using an awl.
3. After the holes are ready, it is worth treating them with glue or other means to seal the structure. Processing is carried out immediately before assembly so that the glue does not dry out.
4. Then we fasten the fittings, fix them with nuts. The pipe to the inlet of alcohol-containing vapors should be 1–1.5 cm lower than the outlet pipe. The pipe through which harmful oils escape is lowered into the sink.
5. We place a dry pot between the refrigerator and alembic. We use silicone hoses for installation, since rubber can affect the taste of the drink and its smell.

Several reflux condensers can be made using such a system; in principle, the circuit is not particularly complicated. You can "screw" a sump to a ready-made unit or add it to a self-made moonshine still.

After the dry steamer is ready and built into the structure of the device for the production of alcoholic beverages, it will need to be tested. It is worth pouring water into the distillation cube and starting the device - this will help check the tightness of the connections and the correct installation.

Dryer for rectifier

The presence of a drawer in the device does not mean that it has a rectifier. The tsarga is a part of the distillation column, but not only this device is involved in the distillation of alcohol. So, how to strengthen the work of the tsargi and turn the moonshine still into a real distillery? To do this, you can equip an existing device with an additional module - a dephlegmator.

How to make a dry tank for a rectifier:

• To make a dry pot, you should arm yourself with a thermos and disassemble it. To prevent damage to the device, it is necessary to clean the bottom of the thermos, remove the staples and carefully disassemble the device.
• After the thermos is disassembled, it is worth starting to turn the front seam. The weld is turned until a gap appears.
• When the gap is ready, you need to pull out the inner capsule of the thermos and weld the ventilation tube to it.
• Then we fix the test tube to the bottom of the structure.
• Then we solder the neck to the gap node, a hole must be made in the neck, a tube will be mounted in it.
• We prepare the hole in the sleeve, the sleeve is made of fluoroplastic and serves to strengthen the tube.

The design of a reflux condenser for a distillation column is very complex, making such a device with your own hands is not at all easy. For this reason, you can buy a ready-made device, it will be easier.

It is worth noting that earlier the dry steam tank was considered an unnecessary element, the equipment for making moonshine with a reflux condenser was not very popular, and the units were dismantled. The sediment tanks were removed without thinking that they improve the quality of alcohol and its taste characteristics.

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