DISTILLATION - HOW IT WORKS
The purpose of this paper is to describe the process of distillation in the hope that those interested in home
distillation may achieve better results in what they are trying to do. It is a basic description only, and thosewith rigorous scientific leanings should feel free to contact me if they find any alarming errors of fact.
However, I ask that criticism be tempered with the intent of the paper in mind.
Vapor pressure.
Every substance is a collection of molecules held together by mutual attraction. The temperature of that
substance is a measure of the kinetic energy these molecules have - the faster they vibrate about their mean
position, the higher the temperature. Depending on the temperature and the pressure under which thesubstance exists, the molecules may pack together tightly as a solid, may pack together loosely as a liquid,or may freely move around as a vapor. These states of matter are termed phases, and the transition fromone phase to another is almost invariably sharply defined by temperature and pressure. It may be noted inpassing that some substances pass directly from the solid to the vapor phase - they sublime - but I don't
think that many reading this will be interested in the behaviour of mothballs!
Having established that there is an orderly transition from one phase to another, the spanner in the works isthat both solids and liquids lose molecules to the vapor phase directly - so perhaps we should be interested
in mothballs! They do this by having enough energy to escape a barrier at the surface caused by the factthat when inside the solid or liquid the attraction of other molecules is evenly distributed in all directions,but at the surface is directed solely towards the body of the substance. This is a potent force manifesting
itself in liquids by what we call Surface Tension. It is this which causes the surface of a liquid to form ameniscus against the side of a beaker, or to make globules of mercury scoot around like ball bearings.
Many insects depend on it to walk on water! It takes a lot of energy to vaporise a liquid, far more than tojust heat it up, this being the energy needed to overcome the surface tension. Just bear in mind that the easewith which a liquid vaporises is directly related to its surface tension and that the lower the surface tension
the more molecules will be in the vapor phase to contribute to the vapor pressure.
The vapor pressure of a substance is the contribution these freed molecules make to the pressure of the areasurrounding the substance. This may be illustrated in a simple experiment most have seen at school. Takea long glass tube and fill it with mercury. Upend it in a beaker of mercury and if the tube is long enoughthen it will be seen that the mercury will be held up in the tube as far as the surrounding atmosphericpressure enables it to do - a vacuum being left in the top of the tube (purists - please ignore the vapor
pressure of mercury and glass!). Now introduce a few drops of water into the bottom of the tube. These
droplets will float to the top of the mercury column and will be seen to boil rapidly. Eventually, you willbe left with a few drops of water floating on top of the mercury column and the mercury column will havelowered by about an inch or two. The lowering of the mercury column is a measure of the vapor pressureof the water at that temperature. Increase the temperature and you will need more water and the mercury
column will reduce even more. At around 100 degrees Celsius the tube will finally be empty of mercury
and contain just water vapor. The vapor pressure of water, or any liquid, equals atmospheric pressure
at its boiling point for that pressure. Lower the surrounding pressure and you lower the boiling point.
Increase the surrounding pressure, as in a pressure cooker, and you raise the boiling point. This may seemto be an awfully long-winded way of going about describing what happens in distillation but believe me,
it's necessary to have that picture in your mind.
.
Mixtures.
Take pure water and you will have a liquid that boils at 100 deg C (all pressures from now on being taken
to be standard one atmosphere) and has a surface tension of 54.9 dynes/cm2 (1 dyne = force to accelerate 1
gm at 1 cm/sec/sec). Take pure ethanol and you have a liquid which boils at 78.5 deg C and has a surface
tension of 21.38 dynes/cm2. You may therefore have guessed that the ethanol has a higher vapor pressure
than the water, needing as it does less energy to release molecules to the vapor.

Now mix the two. Whatever ratio you have chosen, the boiling point of the resulting mixture will besomewhere above 78.5 deg C and somewhere below 100 deg C.
Now, to dispel a myth. Do not think that because your mixture contains ethanol that boils in its pure state
at a lower temperature than water you can just keep the temperature of the mixture below 100 deg C andyou will be the delighted recipient of pure ethanol that boils off at a lower temperature! Believe me - I
have seen that seriously advanced as the gospel truth!!!
What happens, and this is the crux of the distillation process, is that the mixture boils at some temperaturedepending on the relative concentrations and produces a vapor that is a mixture of the two substances.
However, not just any old mixture. Remember that bit about vapor pressure and the energy to releasemolecules from a liquid? The substance with the highest vapor pressure will contribute more molecules tothe resulting vapor than will the substance with the lower vapor pressure. So, whatever mixture you started
out with, you end up with a vapor that will be richer in ethanol molecules than water molecules. Excellent!
You can now condense this vapor and enjoy a good drink, which is exactly what they did in the Good Old
Days. Of course, it didn't take long for cunning processors in those same Good Old Days to work out that
if you went through the same process again then you would end up with something even richer in ethanol,and so on…
However, and there's always a 'however', what has been described with water and ethanol also applies toother substances, many of which supplied the flavour to the resulting drink but which had lower vapor
pressures than ethanol. The result of repeated distillations was therefore more of the intoxicating stuff, butless and less of the tasty stuff. The end result was, as usual, a happy compromise. Booze produced in bulk
was distilled two, three, or even four times, but then either 'treated' or left to mature (more on this an a
moment) before being consumed. This was fine for bulk as there was enough 'float' to tide you over until
the good stuff matured. In other cases, where bulk wasn't the prime mover, another approach was taken.
The ethanol was distilled and distilled to make it as pure as possible. At the same time, flavours wereseeped or distilled from botanicals to form the basis for flavourings. The two were then 'married' as you
would a perfume and other substances added to produce the exact flavour and palate you were seeking. In
general, the results required less maturation than their bulk cousins, but often benefited from this as well as
many subtle flavours couldn't be manufactured in any other way. This approach fitted in well with themonastic life of the church as a) they had extensive knowledge of herbs and the patience to experimentwith different combinations, and b) the resulting product was clearly not in the same class as the Demon
Drink of the masses. It could even be said to be Spiritual!
Cleaning and Maturation.
A few more myths to be dispelled here!
Carbon treatment of raw spirit is as old as the hills. No doubt others who have researched ancient matterswill be able to fill in the blanks, but it would not be far from the truth to say that wooden barrels were firstused for this purpose as they were the usual containers for anything liquid. Steel containers are now thething. Old wine barrels were, and still are in many places in the world, favoured for brandies as they imparta nice colour and subtle flavour both from their previous contents and the wood. However, before using
old wine barrels, it would have been prudent to sterilise them as best you could to get rid of all the old
moulds that grow apace when the barrels are empty. Fire was (and still is) the quickest and best way ofaccomplishing this without a lot of work and introduction of strange flavours, and if the resulting carbon
had anything to do with the cleaning the stored spirit as well - although not very likely - so much the better.
However, we now know a bit more about the action of activated carbon in adsorbing chemicals, both fromthe spirits trade and from the manufacture of respiration masks. Activated carbons are 'custom built' for
their end purpose, generally involving careful selection of ingredients and very high temperature and gas
treatment. It therefore pays to be careful about choosing the type of activated carbon you use to clean aspirit. Aquarium carbon will not do! It is a cheap and nasty mixture of all sorts of charcoaled substances
containing bits that may well clean the congeners from the spirit, but also containing bits that will introduce
rather nasty trace elements and flavours to your hard won product. Fish won't mind, but you will! Properlysourced activated carbon is on the market now, specifically designed for the purpose of cleaning andpolishing spirits.
As for maturing, this has nothing to do with the cunning ability of congeners to 'seep' through the wood anddisappear, leaving stupid ethanol behind. If it did, then uncounted vintners around the world are wasting
their time laying down cellars of wine, carefully bottled in glass. Maturation is rather more complicatedthan that - it's a number of slow chemical reactions whereby the large organic molecules comprising the'nasties' are broken down into esters and other flavour enhancing chemicals. It may be that cunningchemists have come up with commercial ways of hastening this process, but in general it remains the mostpractical and cost effective way of making wines and spirits more palatable. Unless - and there is always
an 'unless' - you follow the route of the monasteries.
Pot Stills.
Starting from the beginning, many simple stills weredevised - and some from China not so simple - but all
sharing the same basic principle: if you boil up a liquidcontaining ethanol in a pot and condense the vapor thenthe resulting liquid will contain a higher percentage of
ethanol than when you first started
If you repeat this several times then you will end up
with more and more ethanol.

The first type of still was called an Alembic, although
this properly referred to the cap with a spout that sat on
top of the boiling vessel. It worked well, and withvariations to make use of modern materials is just what
you need to distill botanicals. The second isreminiscent of the moonshine contraptions still used(and raided) in America, but without the cooling 'worm'
so characteristic of them.

The problem with both is that if used to distill ethanol then you also end up with all the other undesirable
products - the congeners. Congeners is a term used to indicate a 'family', in this case the family of alcoholsthat are produced when you ferment sugars to produce ethanol. The lightest of these is Methanol, which
because it has the lowest vapor pressure comes through almost in its entirety (also known as the 'heads')
and the heaviest include goodies such as propyl, butyl, and amyl alcohols. In addition to the congeners,
you may also get acetone (ever tried drinking dry-cleaning fluid?) and ethyl acetate which come off withthe heads.
So how do you get rid of them? You can use one of the commercial stills around that are marketed as
fractionating stills (and sometimes even as refluxing stills - but you'll be able to judge that claim foryourself better later on) and chuck away the first lot of distillate that comes across. You are fairly sure to
get rid of most of the heads that way. You can then continue to distill until you are fairly sure that the nasty'tails' are coming through in strength, then stop and run all your product through carbon cleaning andpolishing. This has the advantages that the equipment is relatively cheap and the process fairly quick.
Unfortunately, as we learned earlier in the discussion of mixtures, your middle product is going to be laced
fairly heavily with congeners. The carbon will get rid of a lot of these, but it's messy process and it doesn't
get rid of them entirely. Let me hasten to stress here that I have nothing whatsoever against these stills they are a rapid and economic way of distilling if you take the trouble to go through all the cleaning etc
afterwards. I would hate to have some of my supplier friends accusing me of taking away their business!
However, they are not columns, even if they have a little tower on top, and most especially not reflux
columns.

The Distillation Column.
And now to the crux of this whole thing. How does a distillation column work, and how does it differ froma pot still? This short article will not go into the nuts and bolts of an actual design - for that you need to
get John Stone's excellent book, "Making Gin & Vodka - A Professional Guide for Amateur Distillers" via
his website http://www.gin-vodka.com (but hurry - there are less than 150 left!).

For a start, let's go back to basic principles and think about what
would happen if you heated a mixture of liquids in a boiler and let
the vapor rise in a long column. The first vapor would be richest in
those constituents which have the lowest vapor pressures - theacetone, ethyl acetate and the methanol. Then would come ethanol,
followed by propyl alcohol and water, and with a trace of theheaviest congeners that follow propyl alcohol. This vapor would
rise up the column until its temperature dropped to that point when
this mixture liquefies. Running down the sides of the column you
would now have this richer liquid meeting the hot vapors that are
still rising, and they would boil off again, this time with even richer
proportions of the first molecules mentioned above, but with alesser proportion of the last ones. This would continue the higher
you rise in the column and what you have is essentially what they
have with the big pot stills used to distill whisky.

Now introduce packing into the column. The whole idea is to provide a much bigger surface area onto
which the vapor can condense than just the walls themselves, but without interrupting the flow of vapor
upwards and the flow of liquid downwards. Much more efficient as the surface area of the liquid is greaterand the interchange between liquid and vapor will be faster. It is obvious that the bigger the surface area
we can provide then the more efficient the column will be. So what should the packing be? We arelooking for something that occupies the least volume yet provides the greatest surface area. Spheres?
Hardly, as spheres have the least surface area of any shape. Cylinders? A little better, but not far off
spheres - unless you drill through the middle and make them hollow cylinders. We now have Raschig rings
which are tiny ceramic hollow cylinders that have a much greater surface area than spheres. However, it's
not the direct ratio of surface areas that matters so much as the fact that they pack together more compactly
than spheres and offer even greater surface area volume for volume. There are other esoteric geometricshapes that have been designed, but in the end it comes down to cost as well. Marbles have the great
advantage over Raschig rings in that they are cheap - even if you can get them, Raschig rings are very
expensive. Not to worry though - ordinary metal mesh scouring pads or turnings from a lathe are all better
than even Raschig rings! Just make sure that they are teased out in order to provide that essential path forboth vapor and liquid.
So now we have a long, long perfectly insulated column packed with suitable surfaces onto which vapor
can condense, and then evaporate from again. Make it long enough, and leave it alone to do its thing.
What do we end up with? The first thing to note is that the main difference between a pot still and thiscolumn is that gravity plays an essential part. The process of condensing out and running back down thecolumn is termed reflux. The process of constituents separating out, the lightest (and lowest vapor
pressure) at the top and the heaviest at the bottom is termed fractionating. Lets leave it like this for a
moment and look at a little bit of theory to see what we should be aiming at.

Let's start with a methanol/water mixture with X%
methanol by volume. The top left blue dot charts
the boiling point of the liquid mixture as being Tx
deg C. The vapour from this mixture contains Y%
methanol (shown by the red dot at Tx deg C) andthis condenses at Ty deg C.

Subsequent vaporisations and condensations areplotted in this chart. As the concentration of thecondensed liquid approaches 100% methanol theboiling point, as might be expected, approaches theboiling point of pure methanol: 64.7 deg C.

Joining up these dots gives us two curves. The
upper one may be called the vapour line. Anything
above it is vapour above the boiling point for that
mixture, and anything below the lower liquid line isliquid below the boiling point for that mixture.
It is sometimes said that any point lying in between
the lines represents a transition phase between
liquid and vapour, but a little reflection will show
the fallacy of this view. We chose to start at a
certain concentration of methanol, but anotherconcentration would have resulted in a similar set ofpoints offset either to the left or right of thoseshown.
An area where vapor condenses, hangs around andthen vaporises again is termed a 'plate'. It may belikened to an actual plate or tray fitted in the tower.
Fractionating towers for oils and fuels are actuallybuilt this way.
The figures above relate to a methanol/water
mixture, and are quite simple. In the case of an
ethanol/water mixture we would find that there is akink in the bottom of the curves. This results fromthe fact that ethanol and water form an azeotropic
mixture when the concentration of ethanol is around
95%. Subsequent vaporisation of liquid at thisconcentration will not yield vapour with a higher
concentration of ethanol but one of the same
concentration as the liquid. If we started with amixture that had more than 95% ethanol, then theconcentration of the vapour wold be less and, once
again, the system would tend to settle at theazeotropic point.
Distillation alone cannot give a concentration of
ethanol higher than 95%.

Clever Gnomes have worked out a set of equations which enable you to calculate the number of plates youneed in order to achieve such and such a separation between substances, and it turns out that to achieve
95% separation of a water ethanol mixture you need at least 12 plates under full reflux conditions (nothing
being taken from the tower, but all falling back on itself). I won't bore you with the calculations here, but
those who may be interested may contact me for a full run-down, or search themselves for information on
Clausius-Clapeyron and Raoult equations. Start taking stuff from the head of the column and you willneed even more plates as you would be disturbing the reflux ratio.

Reflux and Balance.
It would be impractical to have an enormously long tower to achieve the separation we require.
Fortunately, there is a little trick that may be used to keep the tower to manageable proportions, yet provide
excellent separation. Left to its own devices, the tower works by condensing out richer and richer mixtures
the higher you go, the condensate running down again until it revaporises and improves the separation.
You can hurry this along by condensing out the vapor earlier by providing a condenser in the head. The
enriched liquid is returned to the column and, in washing down the packing, causes the top of the column tobecome very enriched with the lightest fraction. The column compensates for this rude interference bycompressing the separation between fractions lower down in the column, but this doesn't matter so long as
we confine ourselves to extracting from the top.
Tried and true practice shows that you can achieve almost perfect separation between fractions by using a
tower of about 3.5 cm diameter and around 1 metre long. The secret is to allow time for the process of
wash-down and separation to settle down to a stable condition by imposing 100% reflux for about 4 hours.
After this time, at least the top half of the tower will be filled with almost pure methanol (at the start), as
indicated by the temperatures up the tower having settled down to a stable condition - ie the tower isbalanced. By bleeding off methanol slowly, maintaining a reflux ratio of at least 10 to 1 (return 10 partsfor every 1 drawn off) you can maintain this balance and remove all the methanol with only a small 'blur'when ethanol begins to follow the exhausted methanol up the column. The point at which pure ethanol
starts being drawn off is obvious from both the increased temperature at the head of the column and theclean smell of the product. This will be 95% ethanol - remember it forms an azeotropic mixture with waterand you can't get better than that. Finally, after about 20 to 24 hours (the price you pay for purity), thepungent tails with all the nasty congeners will start to make themselves known.
Conclusion.
So there we are. I hope this article has been useful and not bruised too many firmly held opinions. For
those who hold the latter, all I can say is go and check it out for yourselves. As I have stated before, I
believe there is a place for all types of still, from the simplest alembic to the full reflux fractionatingcolumn. My personal preference is for the latter as I find, despite first appearances, it is cheaper and lesstime consuming in the long run. I also have this funny notion that I should know exactly what's in a drinkthat I guzzle, and by adding known ingredients to a pure product I feel more in control of my destiny.
Incidentally, it's not only booze that I use this product for - as a keen cook I enjoy the opportunity to makemy own food essences.
Mike Nixon
mike@silverkey.co.nz