Many of you have found a sweet spot for your plate reflux column distillation and it runs well. But, for those who are still searching, for new users, those who want to learn more, and for users that might want a different (maybe better) operation, I offer in this thread some insight on this distillation process and give you a way to determine characteristics of your plate reflux column operation.
I am haggy ( aka Haggy ), the retired chemical engineer who analyzed the potstill with thumper operation and created the new Potstill Thumper Calculator that is in the HD Calculator section. That work is detailed in my "Hail the Mighty Thumper" thread.
For the last eight months, I have been analyzing the potstill with plate reflux column operation and have some good information that I would like to share with users of this operation.
I created a simulation of this distillation process and used that to develop a set of calculations that give many operating characteristics of the potstill with plate reflux column operation. I have both an Excel spreadsheet (.xlsx) and a html browser program ( like those in the HD calculator section ). They both take a set of input data by the user and then calculate many different characteristics of the pot and plate reflux column operation. The results are printed out and the user can get an idea of what to expect from the distillation.
The calculations are for 2" , 3" and 4" diameter columns and for 2, 3, or 4 plates in the column. Both sieve perforated plates and bubble cap plates are included. This should cover most users who want to make flavored spirits or get shorter run times or get higher amounts made, but the model is not for a column making close to azeotrope neutrals.
Over 35 different HD posts by users of this operation were studied and used to develop confidence in the calculations. The results are certainly in the ballpark and I think close enough to reality to put this information forward. I studied engineering literature and the flying dutchman's posts to come up with some guidelines on the hydraulics of the column for flooding and weeping and matched that to several posts where they had those problems.
Input Data required for each program is the following:
Input Your Plate Reflux Column Operating Data
Hillbilly Run 1
Column Diameter 4 inch
Number of Plates 4 plates
Plate Spacing 6 inch
Potstill Charge 15 US gal - also can enter this in Liters
Alcohol Content 40 % ABV
Initial Temperature 20 C also can enter this in °F
Power during Heat-up 4000 W
Power during Distillation 3000 W
Distillate rate initially 3.8 L/hr or in pints/hr
Choose Sieve Plates or Bubble Caps 0 = Sieve, 1= BC
Sieve Plate # of Holes 180 - this is set by the program or you can enter a number
Sieve Plate Hole Diam 0.0781 inch
Every input value can be changed to see its effect on the results.
The Results are a long list of the characteristics of the plate reflux column operation using the given input data. I will give the results and discuss them in my next post. The results are items such as the pot heatup time, the reflux ratio, initial pot and column temperatures, the distillate heads and hearts amount made and the expected distillate ABV, the estimated run time, flooding concerns resulting from the column vapor velocity and from the hole/slot velocity, downcomer backup flooding concerns and residence time, the Plate Efficiency, sieve plate weeping concerns, and a power setting to try that may give better plate efficiency. All these things are done for a 2" or 3" or 4" column operation with either 2, 3 or 4 sieve or bubble cap plates.
I have two calculator files. An Excel xlsx file that can be downloaded now and run.
I also have an html file like the ones in the HD Calculator Section. However, this html file cannot be downloaded here. 
I will check this out and try to get it available for all to use. The results are the same using either file.I will follow this post up with the results for the above input data and discuss them. In other posts I will show the likely operating ranges for each size column. The key variables in this operation are the pot charge ABV, the pot power (watts), the take-off rate and the % area of the holes or slots ( the hole size and number of holes/slots ).
Try the Excel file out, compare the results with your operation and give me your comments.