Although there is a significant amount of science involved in the distillation of alcohol, the process is simple enough that it has been produced from rudimentary vessels for centuries. There is even evidence to suggest that it has been done for millenniums. It is not a far stretch to imagine how the basic idea came about. It probably occurred to our ancestors that when they cooked/boiled a fermented wash beer/wine that something magical happened. I would think just the smell of the vapors and how the vapors condense, feel, and taste was an "Ahhh Haaa!" moment. I am certainly not and anthropologist, but in my mind it is reasonable to think that these cultures immediately understood the value in that discovery. And of course, alcohol in spirit form has had uses in tinctures, medicine, perfumes, analgesic, and not to mention direct consumption the moment it started being collected.
Everyone comes to these types of discussions from different understandings and experiences. I think its important to comment on the history of distilling in the United States. This is not really a history lesson but a way to comment on the state of home distilling and the illegality of running a still in this country; also, I happen to live in the U.S.
The United States has a very interesting history with alcohol. We have all been taught that the settlers of the nation left to escape religious persecution and to have better opportunities in the new world. We also know how early Americans felt about taxation without representation...taxation in general. It is no wonder that distillation spread easily across the Americas once free of taxation. In fact, some of our first presidents had their own whiskey and brandy recipes and methods for distillation.
Of course this would not last long, as temperance societies would form and the first whiskey tax would be levied in the states in 1791. Flash forward a number of years, and with great protest, the tax was repealed. Flash forward another decade and we would once again levy taxes against spirits to pay for the war of 1812.
Some considered these taxes as a way to impose temperance. In reality, taxes would increase on the purchase of alcohol to the extent that it became a very real and important way our government raises revenue; not just federal taxes, state taxes as well. However, temperance teachings won out and alcohol was prohibited by the 18th Amendment in 1920. Moonshine as a very real underground industry was born in the United States…
The word Moonshine conjures images of illicit activities happening during the wee hours of the night. Whatever the exact origins of the word, that is precisely what happened across the U.S. during the time of prohibition. Many of the Irish and Scottish families that at some point had immigrated to the U.S., took traditional distilling methods that they learned from the old country. They would become part of the very profitable underground moonshine trade.
The business of illegal spirits thrived through the 20's and the first part of the 30's. Until prohibition ended in 1933. The black market had the rug pulled out from under it and collapsed. Some of us continue to carry on the tradition. We try to study how the old timers have done it, and we try to improve the safety aspects of running a still. As a throw back to prohibition, home distilling has remained illegal. If you plan to construct something to separate alcohol,
you are breaking the law in the U.S.
A little comment on the good ol' days of prohibition.
We can learn A LOT from the good ol' boys in the mountains of Appalachia, and other such places across the U.S. during prohibition. Some of their techniques were questionable, and greed would be too tempting for a portion. Because of this, moonshine has a stigma attached to it. Less than savory methods were used to produce alcohol for sale. They would take cheaper forms of alcohol and blend it with their product; these alcohols were toxic. To make things worse, some of the still construction techniques used were questionable. Many used old vehicle radiators for condensers/plumbing. They would also use lead solder further toxifying the spirit. People did get sick, and it is easy to point the finger at moonshine itself. However, it was poor techniques used, creating what could be a very dangerous product indeed.
Keep this in mind: When distilling, one is SIMPLY separating constituents within the wash you have starting with.
Distilling creates NOTHING. It only distills what is already there. As a result of government propaganda and people's greed, many folks to this day believe that, if you run a homemade still, you will go blind, or get very sick
; a properly made and operated still can cause no such thing! I know I am preaching to the choir on the government propaganda thing…
Don't get me wrong. Plenty of proper methods were used by some of the less greedy. Some wonderful techniques were modified from traditional methods and were cultivated. Here is a video of a man that I find fascinating. I also believe that a lot of the proper methods of home distilling have been derived from people like him.
[video=youtube;hXkoc5-9a-Y]http://www.youtube.com/watch?v=hXkoc5-9a-Y[/video]
Wow, long winded to get to this point, but I think you should know what you are getting into.
It is as simple as heading to the hills:
I am amazed that you can take a few well crafted items and head to the hills. With no access to electricity and only fresh water flowing from the streams. You will fuel your still with what you cut from the land, and you produce an amazing product. You can rely on your sense of taste, smell, and touch to produce the spirit. You do not need a precise control of heat. Therefore, you do not need a thermometer for a basic pot still. These folks made their moonshine mostly at night. They did not want to risk getting caught. I would suggest most of them would need no other light source than the glow coming from their boiler fire.
Pot Still
I was operating my still as a pot still in the video. This is a whiskey/brandy still. Great at providing flavor to the finished product. Produces approximately 65%ABV from a single run from a wash. Can not produce high ABV alcohol without many distillations.
A pot still is a distilling apparatus in a very direct way. Applying heat to a boiler containing a mash or a wash (A solution of alcohol and water -- basically, fermented sugars), that will boil -- turning liquid into gas vapors. Vapors will rise up and follow the path created by the plumbing. The pot still is constructed so that the vapors are directed toward a condenser, through this plumbing, and allowed to be condensed back into liquid. There is not much more to it. The basic pot still that these old moonshiners would use contained at least: A boiler, lyne arm (carries the vapors up and out of the boiler), a worm (coiled copper tube condenser) , and a flake stand (positions the worm, submerging the worm in water). They needed cool water to flood the flake-stand and cover the coil so that the vapors are cooled within the worm, and a collection vessel to collect the liquid distillate. This entire system works because alcohol has a lower boiling point. Applying heat will cause vapors that, at lower temperatures will contain more alcohol with certain proportions to water. There is a reason I did not say that alcohol boils off first -- because it is not entirely true.
I understand my distiller does not look like the above, but it is a pot still nonetheless. Just more compact.
Why Alcohol does not boil off first in a pure sense, and why you can NOT control the temperature of your boiling wash.
Let's get a basic understanding of the wash that you will be boiling. In its basic form, a wash is fermented sugar -- the end result -- a solution of alcohol and water. A mixture. We can call this mixture an azeotrope. It is important to understand that this azeotrope has properties SPECIFIC to this mixture alone. We know that alcohol at sea level boils at 173.4 degrees F. We also know that water boils at 212 degrees F. I know, you are thinking to yourself: "Why not just keep your temperatures at 173.4F and boil off all the alcohol?". Many new to distilling conjure up sophisticated ways of doing so.
It simply does not work that way. This azeotrope you spent fermenting/creating has its OWN physical properties/specific boiling temperature. This is based on the amount of alcohol to water ratio that you have created. It is dependent on the recipe you used and the resultant alcohol to water ratio. Most washes are between 6-14%Alcohol by volume (ABV). Think of it this way… The more alcohol you have in your wash the lower the temperature the solution will boil. If for example you have a significant amount of alcohol in solution, the boiling temperature might be 187F. If you do not apply enough heat to reach the 187F, you will not boil the wash. If you do not boil the wash, you will not produce vapors and you will have zero distillate output.
So for their first run, many newcomers turn on the burner and begin applying heat. They make the foolish decision and put a thermometer in their boiler and they watch the temperature rise. They watch the temps reach 173.4 and wait with anticipation…
NOTHING. They panic and shut the distiller down. They simply have not reached the temperatures specific to their mixture (did not reach 187F) so no distillate output was achieved.
The first mistake the individual made was using a thermometer in a pot still. There is simply no need. Remember the moonshine story, these folks distilled in darkness…they couldn't even see to read a thermometer even if they had one. You can believe they had no idea what an azeotrope was; they would think it was crazy even mentioning it. The only thing that is important in running a pot still is how much heat you apply. Bring the temperature up to boiling, whatever "azeotrope??" blah blah blah, just collect. If you want to collect things faster…turn up the heat. Slower…reduce the heat.
You
CAN NOT control temperatures directly on a pot still. You CAN NOT. You can simply push more heat in…boil more of the alcohol off…and WATCH the temperatures rise as your mixture changes. As you continue to boil more alcohol off, your ratio of alcohol to water changes (you will always be depleting the alcohol as you boil it off). Keep running the still, and you will eventually boil off all of the alcohol; your temperatures will eventually come very close to 212F.
It is important to understand what a pot still is. We will eventually talk about making HIGH ABV (95.5%) alcohol, but we need to understand the pot still so we can understand the reflux still.
Reflux still
This still is a vodka still. Does not produce much flavor as it produces a cleaner/higher ABV alcohol. This still is capable of producing 95.5%ABV. This is how you can produce your own solvent.
A reflux still or fractional column distiller is another still that can be constructed. This still will allow for the collection of distillate up to a max of 95.63%ABV. This is a very high ABV for sure, but it is not 100%. Know that for normal distillation methods it is not possible to collect anything higher than that. This has to do with the azeotropic properties of the solution 95.63% alcohol to 4.37% water. The physical property of this azeotrope is actually MORE volatile than ethanol alone; hence, no ability to separate any further through typical distillation methods. Counter-intuitive and not important that you understand that concept…just know you can’t get better than 95.63% using a reflux column.
The concept behind a fractional column is stacking the lighter vapors and keeping those at the top of the column. These columns are tall. It is essentially performing many MANY distillations on a single run allowing for the take-off at the top. Within this long column you are creating a temperature gradient. We have discussed that the purer form of alcohol, containing much less water, will have a temperature of 173.4F. You simply have to design a way to draw the distillate that has formed from that low temperature. In other words, you collect the distillate that has formed from the lower temperature vapors. You can accomplish this a couple ways with the refluxing mechanism as the primary control.
Refluxing is allowing the formed distillate to be re-introduced back into the column. Meaning, you do not collect the distillate like you do on a pot still. You have to have a valve, allowing the closing of the take-off and recycle/refluxing the distillate back into the column. As you reflux the distillate back into the column/boiler, you stack your vapors in the column; we call this balancing. When the reflux column is in balance, you will have the cooler vapors at the top. You can then crack open the valve and start to draw from the well of distillate that has formed from those lower temperatures. You do this slowly allowing for some reflux to always occur. Imagine the still sending some of the distillate refluxing at all times while you draw only enough as to not disrupt the balance.
The balance is monitored by temperature. SO, for a reflux still you
MUST have a thermometer; much different than a pot still. That thermometer must be at the very top where you will be drawing the distillate. Your goal is to try to keep the temperature at 173.4ish. If you can accomplish this, your take-off will be 95.5ish% ABV. If your take-off is too fast, you will be allowing for heavier/higher boiling point vapors to reach to top…your ABV will drop (less alcohol by volume). You will close the valve allowing for a slower take-off and your ABV should rise as you bring the still back into balance. We will talk about the importance of an alcometer and a parrot later.
The second method used in conjunction with the reflux valve is packing the column. This allows for hot surfaces areas of the packing to constantly re-vaporize/re-distill the distillate; this aids in the stacking. The packing you stuff into your column is usually either copper, or stainless steel scrubbers; although many other safe non-synthetic substances can be used. Yes, just those metal things that you scrub your pots and pans with. They MUST be stainless steel or copper…You can get them in the states at the dollar store 3 for a buck.
The above reflux still that I have been describing is called a liquid management (LM) still. In other words, you use the liquid distillate to reflux back into the boiler to accomplish the vapor stacking. The other two main home distilling reflux columns are coolant management and vapor management distillers. We are going to be connecting with this concept through the distiller I have shown in the video(concentric) and discuss how this is easily modified from a pot still to a liquid management distiller. So logically, our focus with be on liquid management distillation.
This is the same pot still in the video (modified to reflux). If you look close at the top of the column, you will notice a needle valve (that is your reflux control). Close the valve all the way, and distillate recycles back into the column. Some people must let their distller reflux like this(full reflux) for a half an hour or more before vapors stack and the still is in balance. You can also see the thermometer place just under the valve on the top of the packed column. The theremometer will read 173.4F and you know that it is in balance and what you draw off is going to be 95.5%ABV. If the temps rises, you are out of balance and you will need to close the valve some and reflux more. The column has pipe insulation around it.
Ok, that is some of the basics...when I have time...I will get into the meat of things in subsequent posts.