I very much enjoyed reading your post Odin.
Odin wrote:On positive feedback: what I see is this: reflux exciting your boiler will have a higher abv than the wash or low wines you are distilling. If you re-distill them and have the gasses re-enter the column from there, you will introduce higher abv gasses into your column, thus creating a positive feedback which is good.
On gathering tails: re-distilling many times means that, with every re-distillation, tailsy alcs are more and more pushed down, towards the end of the column, where they may stack. If you have the reflux exiting (yet exciting) return to the boiler, the tailsy molecules get mixed in with the wash, which is a bigger dilution factor than collecting them in the re-distillation boiler. If you collect them there, they will give you more smearing of tails earlier in the run, especially when using a non-SPP packing. Other than SPP packing just does not give enough re-distillations to keep them at bay.
I have to agree, stacking of the tailsy components would happen. Lester mentioned seeing some fusel oils floating with rev 0 of the reboiler, and the shorter reboiler rev1 or two is just giving a smaller reservoir of higher abv product to draw from, not eliminating the tailsy product..... just less overall tails to contaminate on the amount going back up the column.
Odin wrote:Temperature in the column is not a good indicator for when tails arrive. Not in your (or mine) approach. With the efficiency boost from the re-distiller under your column and/or with SPP it is (probably) very easy to take any wash abv to 95%. I do not use a re-distiller under my column, but I do use SPP. By upping the RR I can take a 1% wash to 95%+ without any problems. So if I distill a 30% low wines, I can keep the temperature at (say) 78.3 C all the time. Yet ... in the end tails will come over. The more you compact heads and tails, the smaller these factions become. But there is a trade off. And that's that the tastes associated with these factions do blend into your hearts. Good if you want to make a whiskey or brandy, but not good if you want to make a neutral.
I suppose that is a factor of packing efficiency and how well the stacking of fractions is occurring, especially with low wines as a starting point. As I have improved my packing efficiency, i have found that the onset of temperature rise is later and more severe. i.e. the tenth of a degree rise is followed in the next few 100ml by degrees in temp rise... and a definite swing in taste to the tails. I have found my hearts to be cleaner tasting in the last of the hearts jars next to the tails jars than in previous setups. Now I should have prefaced that by noting I am running Birdwatchers sugar washes for neutrals.....
Odin wrote:Another trade off is speed versus purity versus number of re-distillations. If you distill faster at a given number of re-distillations, your hearts will become less pure. Upping the number of re-distillations is the way to compensate for higher gass speeds in the column. That's why using SPP would be your next logical step indeed.
On the re-distillation boiler, re-distilling reflux exiting the column ... is it possible to make a small drain from that? If you take off a few mls after every re-distillation, you will probably get rid of very concentrated tails during the second half of the run.
Just giving it my 2 cents.
Odin.
PS: your numbers of 3.7 liters per hour on a 30 to 40% wash are very good. Given the amount of re-distillations scrubbers give you, I can imagine that it does compromize purity. With the gass speeds associated with the take-off speed you have, you pretty much need to triple the amount of re-distillations not to have smearing. In using 2 kw, I get 3.5 liter per hour out of an 2 incher as well. That's on a 30% low wines charge. If I up the power to 2.8 kw, I can breech 4.5 liters per hour. If I do this, I also make sure there is more reflux going down the column for more re-distillations (closer to 60 on a 120 centimeter of packing).
This is why I have focused more on packing efficiency than worrying about the reflux ratios. If the packing is not up to the task, then increased reflux ratios wont help as much. I would like to try SPP sometime for the fun of it.
I have been using copper mesh and made a very dense packing out of it by rolling it as tight as I could and getting it into the column. I was concerned before the first run as I was sure it was too tight and I might get flooding or vapour channelling due to increased vapour velocity.
I have been otherwise pleasantly surprised. I am running 2"x36 packed section at 2.6-2.8 kW and pulling 4.1litres at the beginning of the run on a 40% low wines charge on the VM takeoff. I am very happy to say the least. My total time for the run on a 26 litre charge from cold start to finished is less than 5 hours. It could be quicker, but I shoot for good heads compression on the front end with my LM head and go slow on the fores draw.