42 l stainless steel still with pressurized water bath, 2 columns, dephlegmator and high-performance cooling - Plus-(without, GH, IH)

DESTILLIERMEISTER JUMBO-Premium WD42 Plus-IH

42 liters of water still, 2 columns
Dephlegmator, high performance counterflow cooling 
Pot still or counterflow distillation selectable
Without, Gaz or Induction firing

The DESTILLIERMEISTER JUMBO-Premium WD42 Plus-IH with pressurized water bath is the youngest member of our distillery family, which is just as well suited for the production of high-quality aromatic fruit brandies as for the alcohol distillation of pure fruit pomace or from starch-containing products such as grain and potatoes. The system is operated in different modes. In the present plant, both rectifier columns are used and, in order to control the distillate withdrawal / reflux ratio, a controllable dephlegmator is used in the stainless steel helmet. The advantage over a pure column system, which has static parameters, is the controllability of flow and return, which makes the firing process more dynamic and variable. Each distiller can determine the optimum operating conditions for his plant. Only basic recommendations for the operation are given here. For pre- and post-run separation, settings adjusted to the respective task can be made. For trailers of classical DC distillation, the dephlegmator can also be easily switched off. The rectification plates can now be removed so that unimpeded heat exchange is possible even via the extension units. For firing smaller quantities, a 12 liter module can also be removed. The lower combustion chamber and the two expansion units can, unlike in previous models, be firmly closed before putting on the helmet, so that even with increasing aging of the seals, the connection between the individual modules remains tight and over the entire height (less consideration rising space ) can be filled. The relevant bubble space is now actually 42 liters and this is also relevant for Customs, which in previous cases, where the pots were not firmly connected and separated by the trays, used only the lower bladder (20.5 liters) .

The actual column and dephlegmator operation is used in countercurrent distillation. There are several variants of the DESTILLIERMEISTER JUMBO-Premium WD42 Plus-IH:

• The double still. For this purpose, in the first fire, the so-called rough or raw firing is driven off in the DC process. The expansion modules are used without bottom and filled with mash. In the second fire, the fine firing, the separation of the various fractions - pre-, medium- and after-run - takes place, in countercurrent process. The Rauhbrand, in the same varieties possibly from several DC distillations, is filled with the use of two columns only in the lower boiler, a maximum of 17 liters. If only one column is used, the 1st extension unit can be additionally filled, with a maximum of 25 liters. The dephlegmator is used for the fine firing.

• A counterflow still with 2 columns and dephlegmator. The mash filling height is now a maximum of 17 liters in the lower bladder.

• A counterflow still with 1 column and dephlegmator. The maximum filling height here is 25 liters in the lower bladder plus the 1st extension. If you want to distill 25 liters in one pass in counterflow mode with two columns, there is an option to enlarge the system by another 11 liter unit. The surcharge is EUR 165, - incl. seal and adapter for the latches. To operate the dephlegmator, the temperature is controlled by the cooling water flow. For this, the present model is equipped at 11.3 with a fine control needle valve. This allows the dephlegmator to be set precisely. The cooler is designed to provide the required cooling capacity for the distillate with the smallest flow of water. The required water flow is therefore dependent on the desired dephlegmatist temperature. Lower temperatures let volatile components through quickly and send less volatile back into the kettle. Therefore, the Dephlegmator is switched cooler for the flow separation, so that he lets pass the flow components, but sends the middle run back into the boiler. When the dephlegmator is operated at a distilling temperature of 79 ° C so that no more distillate is dripping from 15.4, the distillation is in equilibrium. Carefully turn the cooling water flow back a little until the distillate begins to drip again and you can now take samples, as described in the manual (CD "Kolonnenbrennerei"). It is important that you have to determine the optimal dephlegmator temperature for the particular type of fruit for your own plant. If the dephlegmator is operated too cool, individual flavorings will not be distilled out clearly enough. If the operation is too hot, the dephlegmator loses its effectiveness.

    
  
  
    

   

Construction

Der Wasserbadkessel

1. Water bath boiler

   This is filled for operation with 9 liters, distilled as much water. On delivery, the boiler is assembled with the mash kettle 4 and tightly glued specially and can not be dismantled. The filling takes place via the ball valve 1.1 of the water bath boiler. For this, the screw 1.3 must be open. After operating the boiler, the boiler pressure is released via the red wheel 2.2 and the safety / manometer module 2- / 3 dismantled and 1.2 closed with the stopper 18.1. The mash kettle 4 can then be emptied and refilled without having to worry about the water bath water. For operation, modules 2 and 3 are reassembled.

   1. Screw nipple for fastening the clamping locks 8.

   2. Screw connection for the safety module.

2. Security module

   The water bath system may only be used when fully closed. That means, all fasteners are closed. This limits the boiler pressure to about 150 mbar. For the operation of the still, the boiler pressure should already be reduced from 150 mBar, which is sufficient for the distillation process. The safety valve 2.3 opens from 150 mbar and releases pressure. If the heating power is too high, it can sometimes rise to 200 mbar. In this case you should reduce the heating to get back below 150 mBar. The boiler was tested up to a pressure of 500 mbar. Excessive pressures also cause the distillation to be too vigorous, so that higher pressures are also counterproductive in the matter.

   1. Nipple for the screw connection to 1.2.

   2. Safety valve 1.5 bar. By turning the red wheel the pressure is taken from the boiler. This valve opens automatically from 1.5 bar, if the valve 2.3 fails in the unlikely event and is therefore also an additional safety level.

   3. Safety valve that opens at a maximum of 150 mbar and releases pressure. The setting of this valve should not be changed unless you know what you are doing. The raising of the valve is prevented by a blocking agent. The blockade can only be lifted by force.

   4. Steam outlet for pressure release

   5. Connection fitting for the pressure gauge module.

       
      1. 
3. Manometer-Modul

   1. Connection nipple for screwing to 2.5.

   2. Manometer-tube. This serves to protect the manometer from high temperatures. It is filled with water for operation.

   3. Manometer scaled up to  600 mBar.
       
4. 20,5 Litres Waterbath-Mash-Boiler

   This is glued on delivery tight with the kettle. There is no need to uninstall this. It is sufficient to fill the waterbath with 9 liters of distilled water, and after use close tightly with the supplied screw plug. As steam escapes through the safety valve during use, it is sometimes necessary to refill the water bath boiler.

   

5. Lower combustion pot extension or column, 12 liter volume (nominal 11 liters, as the pot to the gasket is slightly immersed in the combustion bladder.

   1. Removable rectification bottom. Without this soil, this unit will be used as a fuel base extension. With the soil in place, this unit is used as a column.

   2. Aroma enhancement by vapor bridges in the column bottoms. The vapor rises through the vapor bridges and initially swirls in the columns. The more volatile constituents continue to rise, the heavier ones condense again and drop back over the sieve bottom. Thus, there is a dynamic multiple distillation in the columns, which is also referred to as countercurrent distillation.

           

6. Upper combustion chamber extension or column. This must always be installed as the last top, because it has the counter hooks for closing the boiler (6.2) and the tension locks for sealing the helmet (6.1).

   1. Tensioning hook for fastening the helmet,

   2. Counter hook for closing the kettle,

   3. Removable rectification bottom as above

   4. Aroma bridge.

      1.     

7. Distiller helm with built-in dephlegmator

   1. with screw connection for mounting the bridge module (10).
   2. High quality stainless steel analog thermometer for the measurement of the dephlegmator temperature. The thermometer has the accuracy class 1.
   3. Process water inlet for the supply of the dephlegmator via the hose 15.2 from the process water module (12.4).
   4. For draining the used water, it flows from 7.3 via the hose 15.3 via the process water module (12.5) and is discharged via 12.6 and one of the hoses 15.1.
      

8. 6 two-stage latches
   These are attached to the screw nipple 1.2 and secured by wing screws.

   

9. Safety hooks for the water bath boiler

   

10. Connection module with steam pipe system and thermometer

    1. 1" threaded nipple for screwing on the helmet.

    2. Stainless steel analogue thermometer of high quality for the measurement of the distillation temperature. The thermometer has the accuracy class 1.

    3. Connection fitting for the high-performance cooling module (11).

       

11. High performance countercurrent cooler, 6 m stretched length

    1. Screw nipple for screwing to 10.3.

    2. 6 m double tube, in the soul the distillate flows downwards, between soul and mantle the cooling water in countercurrent upward.

    3. Cooling water inlet with fine adjustment needle valve,
       

    4. Process water outlet to the dephlegmator with connection nipple for the hose 16.2 with pinch cock for fine adjustment.

    5. 6 m spiral double tube, soul inside for the distillate and outer coat. Between soul and mantle, the cooling water of the distillate flow direction runs upwards to the process water outlet 12.3.

    6. Distillate outlet. Here the distillate line 16.4 can be plugged.

       

12. Process water module for water supply of the dephlegmator

    1. Screw nipple for connection to 12.3,

    2. High quality stainless steel analog thermometer for the measurement of dephlegmatist temperature. The thermometer has the accuracy class 1.

    3. Shifter Dephlegmator on / off. When the lever is in the picture, the dephlegmator is switched on.

    4. Process water outlet to the dephlegmator with connection nipple for the hose 16.2.

    5. Wastewater inlet from the dephlegmator with connection nipple for the hose 16.3.

    6. Connection for one of the hoses 16.1 for wastewater discharge.

                      

13. Stainless steel support rods for rebuilding the pipe system

    1. Lower part of the stand tube for holding 11.

    2. Upper part of the stand tube for holding 11. Insert into the socket of 14.1.

    3. 3 support rods for mounting the cooling module 12.

       

14. 4 Stainless steel cross sleeves for fastening the pipe system to the support rods

            
15. Tube set
    1. Water hoses for screwing to 12.2 (water supply) and 13.6 (water disposal.)
    2. Connection of process water module (13.4) with dephlegmator input (7.3).
    3. Derivation of dephlegmator water from 7.4 to 13.5.
    4. Distillate pipe to attach to 12.5.
       
16. End plug to

    1. Closing the water bath boiler,
       Closing the manometer tube.

       

17. 3000 Watt Buffalo-Induction heating for heavy use
    Stainless steel housing,
    10 Power levels,
    Timer 0-180 minutes,
    Removable filter to protect the cooling fan.
     

    

18. Adjustable roller base for easy removal of the still

      

Operation of the water bath distillery
This new type of distillation master series is a highlight in the low cost both for the production in the small burner range as well as for friends of the experimental distilling. The burning of mash, especially fruit mash with residual starch, is a thing of the past. Burn liquor, especially in the fruit distillery, can now be realized on a small scale without burning the mash with a pressure water bath still. This pressurized water bath still is operated with a maximum pressure of the water bath space of approx. 150 mBar. The temperature of the water bath is then about 103 ° C, so that the mash can be easily heated to the boiling point of the water and the distillation proceeds slowly enough, so that quiet separation of the components is guaranteed. For safety reasons, b opens an overpressure valve approx. 150 mBar, so that the temperature of the waterbath is limited to a maximum of 104 ° C.
Filling and closing
At the beginning of the kettle is filled through the opening 1.2 or the cock 1.1 with 9 liters distilled water as possible and then screwed once the plug 16.1. It should be noted that the two provided for the discharge between water and mash kettle safety hooks 9 remain taut between the handles. To firmly connect the mash kettle 4 and the extension units 5 and 6, the latches 8 are connected and placed in the hooks 6.2 and tensioned Now the system can either be filled with mash up to the maximum capacity con with about 34 liters or the bottom mash kettle for a Feinbrand be filled with up to 18 liters of roughened fire. When mashing, make sure there is enough liquid in the mash kettle. Although the mash can no longer burn, liquid is beneficial for effective heat dissipation in the kettle. The maximum filling level takes into account that the mash still expands when heated and possibly also foams. One should therefore always be below the maximum possible filling volume when filling. Depending on the application, the upper column can also be filled with fruits or herbs. If you only want to burn once, so do not want to create a raw fire and later fine firing, the columns must remain free in any case, to ensure a sufficient separation performance for pre-middle and caster. If mashing of the same variety is planned in several sessions, the system does not have to be completely cleaned after each session. For refilling, the bridge at 7.1 can be detached from the helmet (careful, hot, wear gloves). The pressure of the water bath is discharged at 2.2, the safety module unscrewed at 1.3 and the plug 16.1 screwed. The boiler system can now be removed; the distilling structure stops without a kettle. After emptying and brushing off any starch build-up from the mash kettle wall with hot water, the system can be refilled directly.  Now the boiler can be pushed back in and the distillation system and the safety modules can be screwed on; first the module 2. The manometer tube 3.2 is now, if not already done as a heat buffer to protect the manometer filled with some water; then the module 3 is screwed to 2.5. The tube can then be flexibly rotated so that the pressure can be read conveniently.