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You can put different packings into a distillation column and it will work, but in different ways. When choosing a filler for a column, you need to take into account its characteristics (pipe diameter, its height). Fillers for distillation columns are different, the most popular of them are: (SPN) Selivanenko spiral prismatic nozzle, (RPN) Panchenkova, Rashig rings, ordinary kitchen sponges from of stainless steel, broken glass, and etc.
The nozzle is necessary to hold the largest volume of phlegm on its surface, and also to allow the flow of alcohol vapor to pass freely. Interacting between reflux and steam, they ensure the separation of the water-alcohol mixture into various fractions. Therefore, the larger the surface area of the nozzle, the better the separation will be.
1. SPN
Spiral prismatic fillers have been invented quite recently. SPN Selivanenko was the first of them. Now some modifications of this attachment have appeared, for example the 10-sided Diogenes SPN. Currently, the spiral prismatic nozzle is considered the best for use in home moonshine stills and distillation columns Oh. For household mash columns and distillers, it is better to use copper SPN; according to some data, it softens the taste of the distillate.
SPN is made of stainless wire with a thickness of 0.2 0.25 and 0.3 mm. Consists of 4x4 segments; 3.5x3.5; 3x3 and 2x2 mm prismatic spiral. The smaller the nozzle, the higher the quality of the resulting product, but the lower the productivity, and with a large nozzle, the selection speed increases, but the quality of separation is lower.
The nozzle is poured into the column and lightly compacted every 10 cm; for this it is convenient to use the handle of a shovel. For a household column, it is easier to purchase a nozzle from a trusted seller, because Lately There are many fakes on the market. The price of the Selivanenko SPN nozzle is about 1500-2500 rubles per liter, 1 liter depending on the type of wire, weighs approximately 1.2 kg.
You can make SPN with your own hands at home. To do this, you need stainless steel wire, a winding device (usually a drill or screwdriver), and the finished cut nozzle must be etched.
Video on how to make SPN with your own hands
2. On-load tap-changer
The second most popular Panchenkov attachment is used in home distillers and homemade distillation columns to increase the strength and increase the degree of purification of alcohol. The RPN (regular wire nozzle) was created at JSC Tupolev. This attachment has high efficiency and is used in many expensive household stills and rectifiers.
Convenient to use, the rolled nozzle can be easily inserted and removed from the column for cleaning. The on-load tap-changer is woven from stainless thread with a thickness of 0.13 mm. Zigzag weaving, very thin, gaps between threads no more than 1 mm. Used in pipes with internal diameter not less than 30 mm. The regular nozzle has proven itself excellent among home distillers.
3. Rashig's rings
Raschig rings are made of ceramic, metal or glass with a rough surface so that the phlegm stays on the surface longer. This type has long been used in distillation columns. Raschig rings are less popular, but are nevertheless used in many devices as an attachment.
4.Washcloths
Most a budget option attachments - ordinary kitchen sink scrubbers, which are sold in any supermarket. They are usually made of stainless steel, so they will be suitable as a filler for columns. Of course, the quality of the alcohol will be an order of magnitude lower, and during distillation, changes in the taste and smell of the alcohol may occur from the sponges.
Sooner or later, all device owners face the problem of choosing the optimal nozzle. column type. Usually the decision is made based on the recommendations of the column manufacturer or advice on forums. The problem is that often the information on popular Internet resources is not objective, since manufacturers and sellers of attachments explicitly and implicitly sponsor posts that praise their brainchild. In this article, we will try, based on calculations, to objectively evaluate the properties of the most popular nozzles: spiral-prismatic (SPN), regular wire (Panchenkov mesh, RPN) and household metal sponges.
When choosing a nozzle, the main criteria are throughput and separation capacity. Of course, weight and price are also important. Let's tie all these indicators to each other to understand what we get for our money.
SPN 
on-load tap-changer 
Washcloths Let us immediately make a reservation that the separation and throughput capacity of the column depend not only on the properties of the packing, but also on other factors: reflux ratio, heating power, vertical position of the column, quality of packing filling, heat loss, etc. Therefore, when evaluating the packing, we will only disassemble it possibilities and limitations, without reference to a specific type or design of column.
The separating ability of the packing is determined by the contact surface area between the steam and the reflux. In other words, the surface area of the wetted nozzle. Throughput is the volume free from packing and reflux.
Both of these quantities can be determined by simple calculations. Let's make them using the example of the popular SPN 3.5 nozzle. The following characteristics of the nozzle will be needed as initial data:
- weight of one liter (P) – 1050 grams;
- wire diameter (D) – 0.25 mm;
- if the nozzle was etched, you need to take into account the etching depth (Ht) - 0.01 mm and the density of the material (Ro) - 7.9 g/cm³;
- Let us take from the experimental data the value of reflux retention by one liter of nozzle (Vf) - 150 cm³.
1. In one liter of column volume the nozzle will occupy (cm³):
V = 1050 / 7.9 = 133 cm³.
2. The diameter of the etched wire is (mm):
Dt = 0.25 - 0.01 = 0.24 mm.
3. Contact area of steam with 1 liter of wetted nozzle (cm²):
S = 20 * ((2V + Vf) / Dt);
S = 20 * (2 * 133 + 150) / 0.24 = 34667 cm².
4. Capacity of 1 liter of wetted nozzle (%):
Rsp = (1000 - V - Vf) / 10;
Rsp = (1000 – 133 – 150) / 10 = 71.7%.
It is quite simple to link the cost of the nozzle to the obtained characteristics. Let's divide the price of the nozzle by the contact area and throughput, and as a result we will get how much we paid.
An etched nozzle SPN 3.5 made of 0.25 mm wire costs about $33 per 1 liter from the manufacturer. So everyone square centimeter the area of contact between steam and reflux costs 0.1 cent, and each percent of throughput costs 46 cents. But these numbers don't say much on their own. Let's compare a nozzle made from different thicknesses wire, which has a different weight per liter.
| SPN light | SPN average | SPN severe | on-load tap-changer | |
| Nozzle weight (g/liter) | 800 | 1050 | 1800 | 450 |
| Wire diameter (mm) | 0.2 | 0.25 | 0.4 | 0.24 |
| Contact area (m²/liter) | 3.5 | 3.3 | 3 | 2.1 |
| Throughput (%) | 75 | 72 | 62 | 79 |
| Price per liter ($) | 28 | 33 | 60 | 22 |
| Cost of 1 sq. cm contact area (cents) | 0.08 | 0.1 | 0.2 | 0.1 |
As the weight of one liter of nozzle increases, the cost of separating capacity increases, and you get the same result for more and more money. In addition, throughput decreases, which means that flooding will occur earlier and, in general, you will have to work at lower productivity.
At first it seems that the on-load tap-changer is the most profitable, the cost of its separating ability is the same as that of a medium-weight SPN, the problem is that the separating ability is one and a half times worse.
Among popular attachments such as RPN and SPN washcloths, the undisputed leader in separating ability is SPN.
This is confirmed by the practical conclusions of distillers. For example, an experiment on distilling alcohol diluted to 40% on a half-meter drawer. After a small selection of “heads”, 100 ml of alcohol were selected sequentially and under the same conditions with a drawer filled with SPN, RPN and washcloths. As a result, when using SPN, the selection strength was 96.4%, RPN - 94.4%, and washcloths - 93.2%. This clearly illustrates the capabilities of these attachments.
If a serious gap between SPN is generally predictable, then the large gap between washcloths and RPN is not perceived at first glance and contradicts generally accepted dogmas. But the experiment is not complicated and anyone can easily repeat it.
If we talk about the cost of filling a column with nozzle, then there is something to be surprised about. In order to fill a 1.5-inch column 1 meter high, you will need either a pair of washcloth wads and 1 liter of SPN nozzle costing 1,750 rubles, or 10 RPN wads 40 cm long, totaling 1,250 rubles. For a two-inch column with a height of 60 cm and having the same volume, you will need 6 on-load tap-changer wads worth 1,350 rubles. Are the savings as great as is commonly believed? This is more of a self-deception.
When analyzing the capabilities of the nozzle, do not forget that despite the fact that a thin wire nozzle shows the best calculated results, it can wrinkle. This will lead to local compactions, which will become areas of choking or hanging phlegm.
The optimal wire diameter for SPN 2 is 0.2 mm, for SPN 3 – 0.22-0.25 mm, for SPN 3.5 – 0.25-0.28 mm.
For example, compare a nozzle with a density of 1600 g/liter and a wire thickness of 0.25 mm with a nozzle with a density of 1200 g/liter and a wire thickness of 0.35 mm. At first glance, the difference is not obvious, but using the graphs, we see that the first nozzle has a contact surface area of about 4.5 m 2 /liter with a throughput of about 600 cm 2 /liter. The second keeps the indicators at 2.3 m 2 / liter and 750 cm 2 / liter, respectively. It is obvious that the separating ability of the first nozzle is incomparably greater, the choice between them becomes clear.
In conclusion, it would not be amiss to remind you that you cannot believe the established dogmas about the cheapness and effectiveness of certain attachments. You need to recalculate everything yourself, and not become a victim of paid advertising. We have provided a tool for this.
A long time ago, when we just started selling our distillation columns, few people were interested in what filled their internal volume - the only thing that mattered was whether they produced good alcohol or not. Then a large tribe of home-made people appeared who were already interested in the type of nozzle (Sulzer, Levin nozzle (SPN), Stedman, Raschig rings), as well as the question: “Which attachment is the best?”. We explain these points as best we can on our website, but, unfortunately, not everyone hears us, and many still think that there is only one “super nozzle” for all occasions. Here is an example of a typical statement: “SPN-3 is cool!”
SPN is made by continuously winding wire on a rotating pyramidal mandrel. A prismatic spiral comes off the mandrel, which is then chopped into elements. Bulk material made from such elements is called a spiral-prismatic nozzle (SPN).
In SPN-3, the number indicates the diameter of the circle described around the spiral, and many are not even interested in the diameter of the wire from which it is made. But the diameter of the wire is one of the most important factors effectiveness of SPN, although there are others. Let's try to figure it out. Let us recall that the rectification properties (or simply efficiency) of any packing are understood mainly as two of its characteristics, which determine the appearance of the column and its capabilities:
- nozzle capacity. Characterizes the relationship between the diameter of the column and its productivity.
- separating ability of the nozzle. Characterizes the relationship between the height of the column and its reflux ratio.
For a specific column, if we exclude from consideration the material and surface structure of the wire, the effectiveness of the SPN is determined by its geometry.
Mandrel shape
In the manufacture of SPN, the wire is wound onto a rotating pyramidal mandrel, with the base of this truncated pyramid can be any “angular” geometric figure, which ensures “self-adhesion” of the wire with the mandrel: plate, triangle, square, rectangle, rhombus, ellipse.
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At one time A.I. Levin and A.S. Zheleznyak introduced the dxL criterion to analyze the effectiveness of the spiral-prismatic nozzle, where d is the size of the edge of the spiral on the mandrel, and L is the length of the spiral element. Those. the geometry of the spiral was “tied” to the geometry of the mandrel.
The shape of the base of the mandrel determines the shape of the future spiral, but not completely. Therefore, it is impossible to immediately say which form of the mandrel base will provide maximum efficiency the nozzle obtained on it. Below, to simplify the explanation, we will consider mandrels with regular polygons at the base of the pyramid.
In our research, as a criterion, we use the real geometric characteristics of the nozzle elements resulting from its manufacture.
They are the ones who determine the effectiveness of SPN.
SPN geometry
Angle at the top of the turn
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Even if there are regular polygons (plate, triangle, square) at the base of the mandrel, the shape of the SPN produced on them will still be very diverse. The formation of the spiral begins at the base of the mandrel (the diagram shows a triangular base). With each revolution, a new turn of wire is placed on the base of the prism and squeezes out the previous turns from it. However, when the spiral leaves the mandrel, it unwinds due to the elasticity of the wire. |
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 Fig.1 |
Moreover, unwinding occurs due to an increase in the radii at each bend of the wire, and the consequence of this is the “opening” of the angles at the tops of the bends in the turns. The degree of “opening” of the corners depends on:
Figure 1 shows a drawing of a “free” spiral turn. Its geometry (and the shape of the entire spiral) is completely determined by the angle φ at the vertices of each angle. It is important to note that due to the “opening” of the angles, the geometry of the coil can be very different from the geometry of the base of the mandrel on which it was obtained. Those. the turn shown in the drawing could be obtained both on a plate (Fig. 2) with a large “opening” of the angle - φ=0º+A2 (very hard wire), and on a triangle (Fig. 3) with a small “opening” angle - φ=60º+A3 (very soft wire). |
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 Fig.2 |
 Fig.3 |
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Spiral diameter and wire diameter
We placed the diameter of the spiral (D) and the diameter of the wire (d) in one section, since according to theoretical formulas (and experimental results) both of these sizes affect both the free area of the nozzle (an analogue of its throughput) and the specific surface of the nozzle (an analogue of its separating ability).
For example, if the nozzle element has a diameter of D = 3 mm, length L = 3 mm and is made of wire with d = 0.5 mm, then the nozzle is more correctly called SPN-3x3x0.5, since, for example, SPN-3x3x0.3 has a greater throughput than SPN-3x3x0.5 at the same angle φ.
But, if you compare two SPNs with equal throughput capacities(these are not equal diameters D), then the specific surface area will be higher for the nozzle that is made of thinner wire.
Element length
The spiral coming off the mandrel is cut into elements, the length or number of turns of which may vary. For some reason, it is believed that the length of an element L should be equal to its diameter L=D (or L/D=1). We will not argue about this, although in our experiments it seemed to us that L/D = 0.75 is better.
Spiral pitch
It is believed that the pitch of the spiral winding should be equal to the diameter of the wire - winding turn to turn. However, to improve the efficiency of the nozzle, it is desirable to provide an interturn gap that does not exceed the wire diameter d.
But you have to make a “sacrifice”. The fact is that, with small d, it is technologically difficult to maintain the accuracy of the interturn gap. And its excess leads to a deterioration in the operational properties of the SPN (tangling, excessive pliability of the layer), and as a consequence, a decrease in the efficiency of the nozzle (due to the ambiguity of laying, lateral penetration of neighboring elements into each other).
Appearance of SPN
Now, having understood the geometry of the turns, you can see how the appearance(shape) SPN depending on the angle φ at the vertices in the turn after winding (not in the mandrel!).
For ease of perception, the shapes of the nozzles in all pictures d, D and R are the same.
Note that the options for SPN forms presented below are purely illustrative, and some of them are practically impossible to implement.
| φ=10º |  |
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φ=15º |  |
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| φ=20º |  |
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φ=25º |  |
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| φ=30º |  |
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φ=40º |  |
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| φ=50º |  |
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φ=55º |  |
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| φ=60º |  |
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φ=62º |  |
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| φ=65º |  |
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φ=70º |  |
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| φ=75º |  |
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φ=90º |  |
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| φ=95º |  |
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φ=100º |  |
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The experiments carried out show that at fixed d, D and R, the efficiency of the nozzle also depends on the shape of the spiral, that is, the angle φ at the vertices in the coil.