Equipment for the production of alcohol at home. Household mini-distillery - the purest alcohol for yourself and not only
As already mentioned, to get moonshine you will need three components: raw materials, on the basis of which alcohol will be prepared, water and sourdough.
The highest quality moonshine is considered to be prepared on the basis of cereals - rye, wheat, oats, buckwheat or barley, etc., as well as potatoes and sugar beets. In addition, berries, fruits (especially apples, plums and pears), beer, starch, sugar, honey, halva, jam, molasses and even sweets are used as the basis. However, rye grains are still in the lead, since the moonshine obtained from them is the most palatable and does not give a severe hangover.
If you want to get a pleasant, mild taste of alcohol, make high demands on the second necessary component - water. Its hardness should not exceed 4 mg/eq. For example, in Moscow before the revolution, water intended for the manufacture of alcohol was delivered exclusively from certain, proven places, which were springs in Mytishchi, in the upper reaches of the Klyazma and the Moscow River.
The third component is no less important. The quality of the prepared product also largely depends on it. Previously, rye sourdough was used, then brewer's yeast, later they began to use artificially grown yeast cultures. In the absence of yeast, they can be replaced with ripe hop cones, from which a decoction is prepared, then added to the sourdough.
The initial stage in the preparation of alcohol is the production of mash, for which all three of the above components are combined in certain proportions. Here are some tips that are useful for both beginners and professionals of the “marching art”.
- How do you know if the mash is ready? To do this, bring a lit match to the container. If the match goes out, then the product is not yet ready. Another way is to taste the mash. Sweetish mash has not yet “reached the standard”. A bitter taste indicates the readiness of the product.
- Braga should be infused in wooden or enameled containers.
– The quality also depends on the temperature. Fermentation should take place in heat. The optimum temperature is considered to be - 50-60 ° C. In the villages, the dishes in which the mash is cooked are usually placed on the stove.
- To obtain vodka with a pleasant taste, smell and color, before starting the preparation of the mash, you can put the galangal root in the starter culture. The resulting vodka will be light brown in color, pleasant in taste and smell. For the same purpose, bison grass, a dried sprig of mint, and ripe red pepper can be added to the starter.
– Never throw away waste. Everything you need to start a new fermentation is added to the used mash. The vodka obtained from such a mash is always of the best quality.
To prepare alcohol, the mash that has reached readiness is subjected to distillation. Note that alcohol produced by single distillation is significantly inferior in quality to alcohol obtained by triple distillation.
And now we give recipes for making moonshine for every taste, because the basis (raw materials) can be a wide variety of products.
Moonshine bread
This is the highest quality moonshine and, perhaps, the most popular. Strong enough, it nevertheless has a mild taste. After its use, there is no severe hangover.
Ingredients: grain (preferably rye) - 4 kg, yeast - 50 g, water - 30 l.
Preparation: pour 10 liters of water into a sufficiently capacious container. It should be hot and not hard (remember, water hardness should not exceed 4 mg / eq.). Pour the grain into the water and mix well, then add another 10 liters of the same hot water, and after a while pour in the same amount of cold water. After adding the yeast, close the container and let the mash brew. After 3 days, the finished mash can be distilled.
Moonshine potato
Ingredients: peeled fresh potatoes - 1 kg, rye flour - 1 kg, rye straw - 50 g, water.
Preparation: finely chop the potatoes, then mash them with a rolling pin and place in a bowl. Add boiling water to obtain a mixture of 20 liters. Add rye flour and straw, let it brew for 2 hours. After this time, you will see that a cloudy precipitate has appeared in the container. Carefully drain the liquid, and again add water to the resulting sediment, the temperature of which is 50 ° C. Mix well. Wait a while and drain the liquid again, combine it with the liquid from the previous drain and place the fermentation container. Distill the finished potato mash. As a result, you will get soft moonshine with a strength of no more than 20%.
Bread moonshine with potatoes
Ingredients: malt (germinated, dried and ground rye, wheat, barley, millet, corn and peas) - 2 buckets, potatoes - 4-5 buckets, yeast - 0.5 kg, water.
Preparation: boil the potatoes and pound them in the water that remains after cooking. Put in a tub. Sprinkle malt flour on top. Again pound until you get an even, jelly-like mass. The mixture should be very hot during cooking. Sprinkle the mixture with the rest of the flour again and leave overnight. After 10–12 hours, stir, pour into a barrel, add yeast. Leave to ferment for 5-6 days. After you can overtake.
Moonshine bread on hops
Ingredients: rye or wheat grain - 1 bucket, boiled potatoes - 2 buckets, boiled hops - 3 l, mash - 1.5-2 l, water.
Preparation: germinate wheat or rye in a wooden trough. Boil potatoes and remember them well. In the mash, that is, the mash left over from the last time, add the boiled hops. Next, thoroughly mix the grain, potatoes and mash. Grain can be ground or passed through a meat grinder.
Put the mash in a warm place. When the fermentation process is over, you can start distillation.
Moonshine from sugar beet
Ingredients: finely chopped beets (based on filling a 10-liter container with it), Poltava groats - 2 kg, water.
Preparation: fill the container with beets, then, filling it with water, close the lid and put on fire. Boil the mixture for 1.5–2 hours, then drain the water into a separate bowl, and boil the beets in the container again, filling with new water. Repeat the operation again.
Pour 5 liters of the resulting beetroot water into the cereal and put the mixture in heat. After 5 days, add 15 liters of the same beetroot water and leave the mash to infuse. After 2 weeks, the finished mash can be distilled.
Moonshine sugar
Ingredients: sugar - 6 kg, yeast - 200 g, water - 30 l, dry currant or cherry branches and / or dry dill.
Preparation: dissolve sugar in warm water and add yeast. Put in a warm place. To get a pleasant smell, you can add branches of currant or cherry, or dry dill. After 6-7 days, the mash is ready for distillation.
Moonshine from chokeberry
Ingredients: ripe berries - 1 kg, fresh kvass (bread) - 10 l, yeast - 50 g.
Preparation: carefully crush the berries, add kvass and yeast. Leave the resulting mixture for fermentation (the temperature should not be lower than 17 ° C). After the end of the fermentation reaction, distillation can begin. It is good to hold it 3-4 times to get higher quality moonshine.
Moonshine from syrup
Ingredients: syrup (any) - 6 l, yeast - 200 g, water.
Preparation: dilute the syrup in water, add yeast. After a week, the mash can be distilled.
Moonshine from apple juice
Ingredients: apple juice - 35 l, sugar - 3 kg, yeast - 200 g.
Preparation: chop apples and grind, squeeze the juice. Add sugar and yeast. Let the mash brew in a warm place, after a week you can start distillation.
Moonshine from plums
Ingredients: plums - 3 buckets, sugar - to taste.
Preparation: mash the plums and leave to ferment for 2 weeks. Water does not need to be added. If sugar is added, then the yield of the product after distillation will be greater.
Moonshine from pears
Ingredients: boiled garden pears - 5 buckets, sugar - 2 kg, yeast - 200 g, water - 5 l.
Preparation: add pears, sugar and yeast to the water. Put in a warm place for a week. After this time, distill the finished mash.
Moonshine from grapes
Ingredients: grapes, yeast - 100 g, sugar - 5 kg, water - 30 l.
Preparation: crush the grapes, leave the juice on the wine, and add yeast and sugar to the grapes (1 bucket). Dilute in water. Insist 1 week, then overtake.
Starch moonshine
Ingredients: starch - 10 kg, yeast - 500 g, sugar - 1 kg, water - 2 buckets.
Preparation: fill the starch with water and brew like jelly. Then add yeast and sugar. Steep for 3-5 days, then distill.
Moonshine from halva
Ingredients: halva - 10 kg, water - 15-20 liters.
Preparation: dilute the halva in warm water. Let the mash brew for 8 days, distill.
So that the moonshine does not have the smell of sunflower oil, add a sprig of mint to it.
Candy moonshine
Ingredients: sweets (with filling) - 5 kg, water - 2 buckets.
Preparation: dilute sweets in warm water. Infuse for 4-5 days, then distill.
Moonshine from tomato paste, sugar and beer
Ingredients: tomato paste - 250 g, beer - 1 bottle, sugar - 10 kg, water - 30 l.
Preparation: pour water over a mixture of tomato paste, beer and sugar. Stir, let ferment in a warm place, then distill the finished mash.
Moonshine "medovukha"
Ingredients: honey - 4 jars of 700 g each (that is, 2800 g of honey), syrup (any) - 3 l, yeast - 300 g, water - 27 l.
Preparation: mix honey, syrup and yeast, add water. Insist in a warm place for a week, distill.
Moonshine "ready in a day" (method 1)
Ingredients: peas - 1 kg, sugar - 5 kg, yeast - 500 g, fresh milk - 1 l, water - 15 l.
Preparation: mix peas with sugar, add yeast, pour warm water. Add fresh milk. Stand for a day, then overtake.
Moonshine "ready in a day" (method 2)
Ingredients: sugar - 5 kg, yeast - 500 g, medium-sized raw potatoes - 25 pcs., Milk - 3 cups, bread - 4 loaves, water - 25 l.
Preparation: combine all the ingredients, add boiled water, mix well. The mixture is fermented for 24 hours. After this time, distill the finished mash.
Moonshine "ready in ... 2 hours"
Ingredients: sugar - 10 kg, yeast - 1 pack, milk - 3 l, water - 3-4 l.
Preparation: very unusual. Pour sugar, yeast and milk together with water into the washing machine. Spin for 2 hours, then let stand for a while and proceed with the distillation.
Drinking ethyl alcohol can be easily obtained at home.
The basis for obtaining the product is starch, which is found in starch-containing plants - wheat and potatoes. Starch is not subjected to alcohol fermentation, so it must be saccharified. This can be done with the help of active enzymes contained in malt, which is a product of the germination of grains of cereals such as wheat, barley or rye.
Getting malt
To obtain good malt, cereal grains must be of high quality: full, heavy, ripe (ripe grains sink to the bottom in water).
They are sifted through sieves to eliminate mechanical impurities, and then washed in water at a temperature of 50 0 C to remove chaff and dust. Then soak in raw water, falling asleep little by little and stirring, and leave for 4 hours.
After that, the soaked grains are covered with a thin even layer (3-5 cm) on a baking sheet and covered with a damp cloth. The room where malt is grown should be well ventilated, it should not be stuffy and damp. These are necessary conditions for the formation of enzymes. The grain must be turned every 6-8 hours and monitor its moisture content.
When the sprouts reach 3 cm, the malt is ready. This takes 9-10 days.
Getting starch
To get starch from potatoes, it is rubbed on a coarse grater, poured with water 1: 1 and boiled for 2 hours to obtain a paste. To obtain starch from wheat or rye, grains must be crushed, poured with water 1: 2 and boiled until a thick boiled porridge is obtained.
The finished product is left to cool to 60 0 C. During this time, the malt is crushed with a blender (or in a meat grinder) and the ingredients are mixed. In order for the starch splitting process to proceed, the temperature of the mixture is maintained at 60 0 C, for which the container is wrapped in a warm blanket or placed in hot water. An hour later, it is released to cool at room temperature.
fermentation
When the mixture has cooled, mashed pressed yeast is added to it. Room temperature during fermentation should be about 20 0 C, then the process will be completed in three days. At a temperature of 18 0 C, you will have to wait a week, and at temperatures below 15 0 C, fermentation does not occur.
Alcohol distillation
In order to get alcohol from mature mash, it is distilled in a distillation apparatus. It can be made according to drawings or purchased factory-made. The principle of operation of such devices is that, under the influence of temperature, it passes into a gaseous state, and then, getting into the cooling chamber, it cools down and condenses, flowing down in the form of a liquid into the receiver.
cleaning
Includes impurities that degrade the quality of the drink and are harmful to health. They should be removed. To do this, a little potassium permanganate is added to the solution and left for a day, and then filtered, trying not to shake the precipitate.
An unpleasant odor can be removed with activated carbon, which is added to alcohol and left for two weeks, shaking the container periodically, and then filtered.
To obtain a liter of alcohol with a strength of 60 0, 100 gr. yeast and 2.33 kg of wheat, of which 1/3 is used as malt. If you make alcohol from potatoes, ¼ of the original product goes to malt.
Ethyl alcohol is actively used in many national economic areas: food, chemical-pharmaceutical, perfumery, microbiological, where it is the fundamental principle of many types of products. Requirements for the quality of alcohol vary significantly, due to the specifics of its use, as well as the characteristics and modes of technological operations in the production process.
The two most popular methods of obtaining it are microbiological and chemical. The first involves the procedure for the fermentation of sugars by saccharomyces yeasts. This technology is widely used in case of mini alcohol production. According to the second method, it is obtained from ethylene by catalytic hydration - this technology is closely related to the use of biological catalytic enzymes. As a result of chemical synthesis, the production of technical alcohol is carried out, and with biological - food and medical.
The main raw material for the production of alcohol is plant mass with a high content of starch, sugar and fiber. In accordance with this, raw materials are divided into 3 main classes: starch-containing (cereals, potatoes); sugar-containing (beet, molasses, grapes, fruits) and cellular (xylem, straw, sulfite-cellulose industry waste). The most popular and economical type is potatoes. The starch included in its composition has a fast digestibility, gelatinization and saccharification. Any grain goes for alcohol processing, including those unsuitable for food and fodder.
Technological process of alcohol production
The production of ethyl alcohol consists of mandatory technological operations, which can be conditionally combined into three stages: preliminary (washing, purification of raw materials, preparation of malt extract and cultures of microorganisms); the main one (boiling the raw mass, saccharification - the transition of starch into sugar, fermentation, distillation of mash and the collection of raw alcohol); final - distillation cleaning.
In the production of alcohol from grain, the raw mass must be distinguished by a high starch content and a moisture content of less than 17%. The preparatory stage of the technology consists in the preliminary purification of raw materials from mechanical, organic and weed impurities. For this, various technological equipment is used: air-sieve, magnetic separators, trieres.
The boiling process consists in the fact that the raw material for the production of ethyl alcohol is treated with a vapor phase of a solution under a pressure of 0.5 MPa in order to soften the cellular structure, swell the starch, extract and convert it into a soluble state to speed up the saccharification stage with enzymes. At the same time, an increased increase in the volume of sugars is carried out due to the breakdown of starch.
To date, the cooking of starch-containing material is carried out by 3 methods: periodic, semi-continuous and constant. The most common is the last option using 2 schemes. According to the 1st operation takes place at a low temperature (about 140 ° C), but for a long time (1 hour). According to the 2nd - the cooking temperature is about 170 ° C for 3 minutes. With this type of brewing, the raw medium moves in a continuous mass through the evaporator for the production of alcohol. In order to achieve uniformity of the flow, the mass is crushed.
The next operation of the food alcohol production technology is the cooling of the prepared medium and its saccharification as a result of interaction with malt solution or enzymes at 58°C. Traditionally, saccharification takes place in a continuous process using vacuum cooling. Cooling in a vacuum apparatus prevents thermal inactivation of the catalyst-enzymes of saccharifying agents. Its principle is to reduce pressure, which causes a sharp cooling of the boiled mass due to the consumption of thermal energy for the evaporation of moisture.
The continuous type of saccharification is carried out according to the 1- or 2-stream method. In the first case, the boiled mixture and saccharifying substances enter the saccharifier (a cylindrical unit with a cone-shaped base and a stirrer), which are kept for a quarter of an hour. With the 2-stream method, the boiled mass is divided into 2 identical streams and sent to the saccharifiers. 66% of saccharifying substances go to the 1st saccharifier, half of the saccharified wort goes to the 2nd. They are cooled and sent for fermentation to the 1st and 2nd main units of the fermentation battery. At the exit, the wort has about 17% dry matter, including 15% fermentable sugars.
Fermentation processes in the wort occur due to the activation of yeast enzymes, while maltose breaks down to glucose and is fermented into the alcohol phase and carbon dioxide. During this process, 3 stages are visible: fermentation, main fermentation and final fermentation. At the initial moment, activation of the vital activity of yeast is observed. The subsequent one is distinguished by the rapid fermentation of the sugar fraction and the strong formation of carbon dioxide. At the final stage, residual fermentation of sugars occurs, which are formed during the sugaring of wort carbohydrates.
The fermentation process is periodic, cyclic and in-line. Maximum efficiency is achieved when using the latter, which is carried out on equipment from serially connected yeast, a fermenter and 10 fermentation units. Yeast and a fermenter are used to prepare the required volume of industrial yeast. In the course of work, the yeasts are filled with wort, it is pasteurized at 80 ° C for half an hour, then it is cooled to 30 ° C, the acidity is adjusted to a level of 3.6-3.8 pH with sulfuric acid and, finally, yeast is added from another yeast for sowing (30% of the volume). The yeast is propagated to a dry matter level in the must of 5%. After that, 3/4 of the volume of yeast passes into the fermenter, where the cooled wort is filled in parallel, the entire mass is acidified to the standard acidity. The last quarter of the yeast is sent to another propagator.
Equipment required for production
Among the equipment for the production of alcohol, one should single out cylindrical-type fermentation units with a sealed hatch to prevent the evaporation of alcohol and the release of carbon dioxide into the premises of the plant. In total, the fermentation stage lasts 60 hours. In distilleries that produce alcohol exclusively, the introduction of test-tube culture of yeast is carried out 1 time / month, and they are completely changed in the fermentation battery weekly. At factories equipped with auxiliary workshops for bakery yeast obtained from mash, the number of replacements increases to 2-3 times a week.
Then the mature mash is sent for distillation. This stage of alcohol production technology is mandatory due to the complex composition of the brew: in addition to water and alcohol, this includes sugars, mineral elements, various volatile components, depending on the type and quality characteristics of raw materials, processing parameters.
During distillation, the mixture is split - when boiled, more volatile elements are converted into a vapor state. In the alcohol-water complex, the volatility of alcohol vapors, regardless of temperature, significantly exceeds that of water vapor, which is why the amount of alcohol in the alcohol-water complex is lower than in vapors.
At modern factories for the production of alcohol, mandatory purification of raw alcohol from impurities is provided. For this, special distillation apparatuses of constant action are used, which cause the separation of a mixture of several elements, the boiling point of which varies. The purification of alcohol by distillation involves the difference between the rectification coefficients (the ratio of the volume of a given component in the vapor phase to the volume in the liquid phase).
These coefficients for various impurities fluctuate and closely depend on the concentration of alcohol. To analyze the need to purify alcohol from impurities, their evaporation coefficients should be compared. In the case where the coefficient is equal to one, distillation is not efficient, since the distillate in the final result will not change. When the coefficient exceeds one, then the volume of impurities in the distillate exceeds this indicator in the initial mixture. When the ratio is below one, the level of impurities contained in the distillate is lower than originally.
Alcohol purification occurs to a greater extent in continuous distillation apparatus, where it is rectified according to the levels of evaporation coefficients. This type of equipment is used in factories where raw alcohol is the main raw material. At the enterprises, rectified alcohol is produced directly from the mash phase on indirect brew distillation apparatuses, which include 3 columns: mash, epuration and rectification. In the 1st, ethyl alcohol and volatile substances are obtained from the mash, in the 2nd, head impurities are removed, in the 3rd, rectified alcohol is directly collected. In addition to the main devices, the composition contains auxiliary devices - fusel and final (for the control purification of alcohol).
The manufacture of alcohol-containing products is carried out if the enterprise has the appropriate licenses for the production of alcohol. Strict control over alcohol production is accompanied by a tightening of highly specialized legislation, an increase in the cost of, regulation of standards for the whole processing of waste.
Many of us know what a mini-distillery is and what function it performs. True, not everyone can afford to purchase such a unit and produce high-purity alcohol at home. Fortunately, you can not spend large sums of money and make a design with your own hands. Consider the principle of operation of a home mini-distillery, as well as the algorithm for its self-assembly at home.
1
Of course, most of us know how much quality homemade alcohol costs these days. In addition, the composition of drinks that we buy in stores may not match what is written on the packaging. In order not to take risks and not overpay, you can go the other way and use the simplest household mini-distillery right at home. With it, you can not only produce highly purified alcohol and all kinds of drinks. Perhaps he will help you open your own business and get alcohol at home, not only for yourself and your loved ones.
To understand how a mini-distillery works, you need to understand the components and basics of making alcohol at home.
Mini distillery for making alcohol at home
Vegetable fibers are considered the main ingredient in creating alcohol with your own hands. These include the juice of berry crops, grain, potatoes, sugar beet and waste from its processing.
A one-time distillation of this raw material at home gives only a preliminary separation of the primary mash. The composition of the latter includes many components, among which there are not only alcohol, but also many harmful products: ethyl acetate, acetaldehyde, ethyl methanoate. The presence of all these components is highly undesirable in the composition of any food product.
To get rid of these impurities, the mash undergoes a reusable purification called fractionation. This process guarantees the production of highly purified home-made alcohol, which can be used not only for making drinks, but also for any household purposes.
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2
The extraction of pure alcohol at home is completely analogous to the industrial production of alcohol. This can be judged by the configuration of modern mini-distilleries. Their design includes the same elements as in the factory settings, only much smaller. It is worth remembering that the presence of certain parts determines the price category of units for the manufacture of alcohol - the more expensive the device, the more components it includes. A household mini-distillery of average cost consists of the following elements:
- unit for water-thermal processing of the mixture;
- apparatus-mixer of pure cultures;
- fermentation vessels;
- mixture distillation unit;
- distillation device;
- installation for repeated cleaning of mash;
- a device for absolutization - the final stage of cleaning the mash.
Complete set of a modern mini-distillery
The unit, which includes all these parts, works according to the following principle. First, the mash enters the unit for heat treatment. There, it is exposed to high temperatures, and also undergoes grinding with a hammer mill in specially created conditions. Then the already crushed mash is mixed with water and alpha-amylase - a special enzyme preparation. After that, the resulting mixture falls under a powerful steam jet and is processed by enzymes. So the mini-distillery produces high-quality and chilled alcohol, which can then be mixed with plant components. As a result of this, craftsmen receive healing or alcohol and other natural medicines.
It is important to remember that in order to achieve a good result when processing mash at home, the latter must be properly mixed. To do this, it is necessary to strictly observe, all components of the mixture must be added in optimal proportions and ferment under certain conditions.
3
Having understood the principle of operation of the unit at home, you can start making it yourself. We will use the simplest materials that can be found at home. As a result, we will be able to save a good amount of money. To make your own hands you will need:
- galvanized bucket with a capacity of up to 8 liters;
- 2 meters of copper pipe;
- clamp and a pair of bolts;
- cold welding;
- aluminum pan or can;
- 3–4 nuts;
- silicone gasket;
- several screw ties;
- 2-3 meters of steel wire;
- drill.
Before proceeding with the assembly with your own hands, we recommend that you make an approximate drawing in which you need to indicate the dimensions and joints of the elements to each other. In addition, in the drawing it is worth noting the number of fasteners used and the volumes of the vessels. So you will not get confused in assembling the device at home.
Drawing of a home mini-factory for the production of alcohol
First you need to make a coil. To make it at home, you can take any cylinder and wrap a copper tube around it. Both ends must remain open so that vapors can enter and exit the coil without obstruction. Next, take a drill and drill a small hole in the wall of the bucket. The hole size must be calculated depending on the diameter of the copper tube. It should fit snugly into the hole and not hang out in it. We pass the lower part of our coil through the hole, while we fix the upper part in a standing position with a clamp and bolts. It is important to pay attention to the tightness of the lower end of the tube. It is best to coat this part of the coil with cold welding.
The next step in the manufacture of the device with your own hands will be the preparation of the distillation cube. To do this, we take a can or pan with a sealed lid, after which we connect it to the apparatus. If the lid does not fit snugly on the vessel, it is best to use a silicone gasket. Remember, in no case do not use rubber, as this material will simply spoil the alcohol with its smell.
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The alcohol industry is engaged in the production of ethyl alcohol from food or non-food raw materials.
Ethyl alcohol, which is produced from food raw materials, then goes into the production of alcoholic beverages, for the manufacture of automotive fuel and the needs of radio electronics.
As a raw material for the production of food alcohol, potatoes, cereals, root crops, sugar syrup or molasses, fruit and berry raw materials and grape products are used - a material that is rich in carbohydrates.
As a raw material for the production of technical alcohol, waste from wood processing or oil refining industries is used. Recently, more and more attention has been paid to the use of plant biomass as a starting material for the production of alcohol. They are subjected to acid hydrolysis. The resulting product contains a large amount of harmful impurities and therefore industrial alcohol is strictly prohibited for use in the food industry.
Alcohol production equipment
The production equipment consists of three departments - a beer column, an epuration column and a distillation column.
The main production line consists of the following equipment: bucket elevator, overhead bin, weighing scales, overhead bin, screw feeder, crusher, mixers, mixing bowl, three-way valves, ball valves, valves, gate valves, pipelines, centrifugal pump, contact head, cooking apparatus, (low-temperature digestion), wort transfer pumps, dosing pump, wort heat exchanger, three-way and ball valves with check valves, fermenters, yeast, trap and mother liquor, mash and yeast pump, sulfuric acid measuring tank, alcohol trap, wash water tank, mash heater, heater water section, condensers, separator, bardoregulator, alcohol trap, dephlegmator, condenser and refrigerator, foam trap, vacuum interrupter, water seal, oil separator, fusel oil collector, alcohol lantern.
Alcohol production technology + video how they do it
“Production technology, in general, consists of three sequences:
- Purification of raw materials from various impurities, preparation of malt or culture of specially selected mold fungi;
- Boiling of starch-containing raw materials, the process of saccharification of starch, followed by fermentation of the saccharified product and distillation of the resulting mash - this will be raw alcohol.
- And then the raw alcohol is subjected to rectification.
Rectification is the purification of the resulting initial raw alcohol. The content of impurities in raw alcohol is so high that its direct use in the food industry is unacceptable.
Harmful impurities that are formed during the production of ethyl alcohol - methyl alcohol - as a decomposition product of pectin contained in plant tissues; fusel oils - or a mixture of higher alcohols - they are initially provoked by protein hydrolysis, and subsequent deamination of amino acids, plus some intermediate products of alcoholic fermentation can also provoke the appearance of fusel oils; esters, furfural. Esters also appear as a result of fermentation processes, when ethyl alcohol interacts with fusel oils and organic acids.
All impurities are classified as intermediate, tail or head.
During cleaning, the difference between the boiling points of alcohols and ethers is used. Ethyl alcohol has a higher boiling point than head impurities - acetaldehyde, esters. And at the same time, ethyl alcohol has a lower boiling point compared to tail impurities - fusel oils and methyl alcohol. Intermediate impurities present the greatest difficulty in the purification process.
During rectification, the finished product is saturated with alcohol from eighty-eight percent to 90-90.5%.
In addition to fusel oils, vinasse and carbon dioxide are also obtained during the production of ethyl alcohol.
Fusel oils are distilled and higher alcohols are obtained, which will later be used in various industries - medical, perfumery or paint and varnish.
The carbon dioxide is purified and liquefied or used to make dry ice.
The post-alcohol stillage is dried and goes to the production of fodder yeast, which is used in animal husbandry as a feed additive.
The classification of the original raw alcohol depends on the content of impurities in it: Alpha, Lux, Extra, basis, highest purification, 1st grade.
Hydrolysis technology has become widespread due to the reduction of fossil organic raw materials. Hydrolysis makes it possible to obtain alcohol from plant biomass, which is a renewable bioresource. In addition to hydrolytic alcohol, synthetic alcohol is also isolated. Its production is based on mixing ethane gas with water under high pressure. At the same time, water and gas are not purified, as a result of the reaction, by-products are formed that are toxic to the human body.
In order to isolate technical alcohol and make it unsuitable for food use, ingredients are added to its composition that change its taste and color with a smell - the color is often obtained with a blue-violet tint. There are certain requirements for additives that are used as denatured alcohol - low toxicity to reduce the risk of poisoning and death, specificity of taste and color, stability as a marker, so that it is difficult to separate it from ethyl alcohol using modern technological processes and equipment.
Video how they do it in vodka production:
To date, most hydrolysis plants in Russia are part of the Ministry of Medical and Microbiological Industry.
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