harley / Falbygdens Bränneri AB Sweden

[harley03]

Left to build!

1pc 8" coppecolumn with 4pc 3"/76mm copperpipe in it x100cm filled with SPP för vodka manufacturing...

1pc 8” kopparkolonn with my sieve plates, then a have 4pc different 8” column that a can both compare and change fast on my 300 liter insulated boiler with 16500watt power.

My 2pc 8” copper column in the picture up have 4pc plates and also sight glass below bottom plate so a can se that the foam issnt going up to the first plate and also 5pc sprayball/ciphead in the back/behind of every sight glass and Off Course drain on every plate becouse if you are comersiell manufakture/craft destiller then you must be abel to clean/wash all plate after everytime you have use the column!

Next winter a shall start to build 300liters insulated boiler in pure copper...

Cheers from Sweden.

[RandyMarshCT]

More beautiful work as always, Harley!

The SPP section sounds interesting. Will it be 4 pcs at 76mm diameter x 1 meter inside the 8" column, all packed with SPP? Similar to a long dephlegmator, but without cooling flow in the jacket?

[harley03]

Hello,

I have measured it and I can fit 4x 76mm tube inside my copper sheet ( so it shall looks same as my other column) in my 8 "/ 203mm copper colon (but it Shall be tight) and I have even thought about filling the space between the outer copper plate and these 4x 76mm tube with foam so everything becomes an isolated entity.

I plan to use my reflux condenser which I use for my other bubbelcaps columns for this column filled with SPP and the top of the column so I will do the walls going up against reflux condenser (like a cross) so all reflux that each pipe give will also fall down in it. .






My thought about this is that you can have a 300 liter boiler and a number of different types of columns at 100cm tall and quickly switch "only" the column to the type that is best suited for the product that you want to make and the hope is that all these must be able to receive 16,500 watts = 3pc 5500watt as max power.

We'll see what happens when theory is replaced with practice!

Cheers

[harley03]

Little 4”column with 1pc 2” single cap with low saw pattern that have/give 6% of column diameter to my 50 liter testplant/boiler is made from 5pc 4” copper pipe sections and also with sprayball in back and drain on side and 2” sightglass also below last plate.
























Cheers from Falköping

[harley03]

1pc 8 1/2 " big singel bubbel caps in a 12" column with a low saw tooth pattern.

The pattern is finish, now a shall made the round roof and hard solder it all together.







4 "/ 108 mm, the maximum size of copper tubing is available as standard here in Sweden, If a want to have thicker/bigger copper pipe so I have to special order it and it is in 5 meter lengths to many big singel bubbelcaps for me....

Then it is better to roll a copper plate strip round and braze with copper plumbing solder on a pressed vaulted ceiling so all the liquid runs off directly.

When you are doing this way you can really optimize bubbelcaps size to the maximum size of the column and get an exactly equal low serrated pattern so all the steam pressed constantly against the plate so no precharge is left on the plate for longer than necessary, and of course so is the ceiling on these big bubble caps round so all Relux runs off quickly ...

Cheers from Falköping

[harley03]

Today's work consisted of rolling 8 x 8 "bubble caps rings and then braze them together.
Became part spills over so possibly it could be a new 4 "column with Maximum size of a single bubbelcaps ... now when I roll them from a strip of sheet metal instead of cut 2" pipe and I must have little to do on Saturday, Sunday also ...
The compression mold to push the roof around / vaulted to these 8 "Ordered in beechwood in 2p pieces of a friend who also will manufacture my oak casks / barrels for storage come ..









Cheers från Falköping

[harley03]

Today's work in the shop made from "Spill bits" left over when we have made them larger columns!

4x 2.5 "bubbelcaps is rolled round and hard soldered together and even roof is made and soldered.

4x 108mm bottoms of plates is the next project to manufacture.

Then a have same pattern in 1pc singel bubbelcaps in 4” 8” and 12” Column











Cheers från Falköping

[badbird]

Love the work you are doing there and am extremely jealous of your workshop
I am planing on making some of your saw tooth patterned 2" bubble caps, as the ones currently in use where cut with tall slots and are far too large.

When you calculate 6.6% of the column cross sectional area for the bubble cap teeth do you subtract the bubble cap area from the column area first before the percentage calculation? Hope that make sense.

[harley03]

The entire column volume! count up all the steam output in the bubbelcaps total volume and this amount should not be less than 5% of the column total volume,but it also works under 5% but you can not use the same high power becouse it can built up pressure and then the plate can floded... ( same as in sieve plates)

Dont fogett to calculate the size of the riser pipe also so you dont get any restrictors there and also between ceiling in caps and to pipe end !

Then you realize that a 2 "bubbelcaps is a bit too small / too low throughput area on a 4" plate and a 2.5 "bubbelcaps would be optimal because then you can have a lower serrated pattern.

it is very difficult to figure out how many low serrated triangles as you can fit ! becouse the height of the judgment will determine how many you will fit around a pipe / caps. so draw up the pattern on a piece of paper first ...

I have decided to put me on 4.5-4.6 mm height with my low serrated pattern ( this a have in 4” 8” and 12” column but also relly Big singelcaps) and big single bubbelcaps as I can fit, so in next 4” column that am build now a have 63mm singel caps insted of 54mm before..

It is very important that the distillation plate is 100% in wave especially when you have 1pc big singelcaps ... and all slots are equal in height / steam release and make sure the entire plate relly/ Truly is 100% tight as in a bath when it works best ... solder everything ...!

But remember that this is my personal thoughts and opinions, everyone does that they want and believe in!



Cheers

[harley03]

Thanks,
a hope that this maybe can help some one maybe!

Cheers from Sweden

[badbird]

Thanks Harley,
That is some excellent advice, I will look at the options for going to 2.5" caps.
Have checked the calculations and luckily when my existing plates where constructed the raisers and down comers where generously sized so I can reuse those with the new caps.
I like the concept of keeping the bubble flow down low and close to the plate but I may go for slightly higher tooth than you just for a little extra leeway in the event of a puke as I don't presently have any other form of pressure relief on the boiler, maybe Its something I will have to look at first.

[Windy City]

Harley Awesome work as always
I am in the process of building a 4" flute and going with your math of 1.6mm holes. I don't understand the question of pressure relief in a flute due to the downcomer. Even if you puke and plug up the perf plate or shallow cut bubble cap the 3/4" downcomer will not let you build up any real pressure. With that being said if it pukes your run is already messed up and I would think you would shut down, clean up and restart.

Just my opinion
Windy City

[badbird]

I am sure you are right about the downcomers, in the future I intend to get into distilling on the grain I guess ill look at the issue again then. Pukes happen on rum washes now and then, its not a big problem, those jars just go into the next charge.

[harley03]

Here you can se the diferense in the pattern betven 4,5mm and 5,0mm Hight on a 4” caps ( the different is massive/ relly big) and 5,0mm was to much/ to big for me so a go with bigger caps with little lower pattern insted and I ended up with 4,5 mm hight ( the pattern to left) but in 2,5” 4,5” and 8,5” caps instead for 2” 4” and 8” caps size and this is note any problem when you roll the caps round and also made the roof from a plate/sheet and hard solder it all together!

Every 0,1mm that you made this pattern higher it grovs a lot to the side allso and you get less number of steam hole.... becouse it is 90 degres, so made it on paper first, thats cheaper




Sorry but my english is note so good, but a hope that you understand me anyway from the pictures.
Cheers from Sweden.

[harley03]

The little 2"/54mm caps/ cutted from a pipe on top have 4mm pattern if i dont remember it wrong and the caps on the botton have 4,5mm pattern and also bigger=63mm and rolled from a plate/sheet..




Cheers from Sweden

[badbird]

I can see from your photograph there is a large difference between the 4.5mm and 5mm patterns and understand the issue with the larger 5mm pattern reducing the number of steam holes. I will draw some patterns up on paper first but your large 4.5mm pattern caps look good so I will probably build something like those.

[harley03]

Cheers från Falköping

[harley03]

Cheers from Sweden

[harley03]

Then it's about time to tig weld together this little 4 "column No.2 entirely in copper which I of which shall be Test Column!

That is seen as one uses what one has to support, to get a straight line to pick up the severed pipe / modules with 1st plate between them, and of course so is every other plate is rotated 180 degrees so the return pipes will alternately ...



Since then, I use a clamp / jack to hold together "package" and since I will tig weld this so I attach not confuse it with gas welding and plumbing lood for it is as "black" afterwards ... but I will clip it on 3-4 points in each joint and then loosen the clamp and put it so I can roll the "package" when I tig welds so I am always on the top and tig ...




This tig wire that is in Silicon Bronze is what I shall use me of when I will join these copper modules on the outside and I hope it works, will also serve and rejoining copper to stainless with ....



Cheers from Sweden

[harley03]

Mate came with press molds for the domed roof of my 8 "bubbelcaps today!




Had a square 1.5 mm copper piece of metal next to me and of course, you had to try it!



I note that you need to anneal the plate and then quickly cool it down so it becomes softer and more malleable before one presses the folded a little easy!




25cm large round plates can I squeeze as maximum diameter and a center hole there through both parts so I also can center and squeeze small plates

Cheers från Falköping

[harley03]

Now begins a 4 "4 plates copper column No.2 with 63mm single bubbel caps coming together slowly but surely.
Unfortunately it does not work forum pictures again .. so click on the links and you will see the picture.

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Cheers från Sweden

[rad14701]

Unfortunately it does not work forum pictures again .. so click on the links and you will see the picture.

Yet another reason to be uploading images directly to this site...

[badbird]

Harley,
These are the bubble caps I ended up making from the information you gave me earlier, they are a bit rougher than yours but thought you might be interested in seeing results.

The caps are oblong 70mm x55mm to better fit the column as my "100mm" tube is smaller than yours, the down comers are 22mm", teeth are ~4mm high.
I lack your precision milling equipment so my teeth ate produced by good old aviation snips

They haven't had much use yet to decide what differences they have made but the plate appears quite a bit more active than with the previous bubble caps at 2200w, anyway I am happy

[harley03]

Looking relly good but you need more power to this 4" with 1pc big singel cap,1pc more element so you can go up to 4000-4500 watt then you shall look at the plate and taste the whiskey / rom

Cheers from Sweden

[badbird]

so you can go up to 4000-4500 watt then you shall look at the plate and taste the whiskey / rom

I briefly ran 4400w and the plate activity certainly looked good but my cooling system in its present form can not cope with that amount of power.
Some changes will be required to make it more effective when I get the time, including re-plumbing to separate the reflux and product condensers, maybe a longer reflux condenser and repairing my power controller

Then the whiskey

[harley03]

Interesting solution for e85/petrol alcohol with the return tubes inside the bubbel caps, unfortunately teaches separation / taste suffer when they can not control Relux fluid way across ENTIRE plate ... but probably it will be an effective flat surface but at the expense of taste ...

The whole distillation idea is that reflux liquid should have as Long way that it is only possible before it reaches the next plate return pipe and with this, you get a much better separation ...

Which is never likely to be the case with this construction with 1pc return tube in each bubbelcaps ...

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Cheers från Falköping

[harley03]

Harley,
These are the bubble caps I ended up making from the information you gave me earlier, they are a bit rougher than yours but thought you might be interested in seeing results.

The caps are oblong 70mm x55mm to better fit the column as my "100mm" tube is smaller than yours, the down comers are 22mm", teeth are ~4mm high.
I lack your precision milling equipment so my teeth ate produced by good old aviation snips

They haven't had much use yet to decide what differences they have made but the plate appears quite a bit more active than with the previous bubble caps at 2200w, anyway I am happy

bc2.jpg

Looks relly good if you only have so little power as 2200watt, the benefit with this pattern and 1pc big bubbelcaps is that the refux, return licuid shall have so long way as possibel to travel before it reach next plate returnpipe so you get a good separation and with much power then this pattern in 1pc big caps relly come to the best in taste transfer and separation...

Cheers from Sweden

[harley03]

Today's work with my little 4 "with 63mm single bubbelcaps is finished, ciphuvud, drainage pipes, sight glass and joint sleeves/ferrule are mounted

Now, the only swim a few days in citric acid and water, and in the meantime it will be the same equipment on my second little 4 "with 54mm single bubbelcaps.

LÄNKTEXT

LÄNKTEXT

I would be very grateful if any moderator could fix / add pictures directly on the forum because I can not do this! Sorry ...

Cheers från Falköping

[harley03]

Todays work…
I have started with a new 12” Copper column for commersiel use and first a made 3pc 220mm bubbelcaps…














Cheers from Sweden

[harley03]