Building The Condenser

Last Updated on Fri, 22 Dec 2023 | Home Distillation

Except for those in the electronic business, everyone knows what a condenser is. It's a device that cools down whatever vapors that flow through it to the point where the vapors condense into a liquid. That liquid is what the rest of the still is all about. In the still we are building, it is also the heart of the cooling system.

Condensers can be designed in many ways, but for a lot of reasons, as you'll see in the next paragraphs, a jacketed core condenser is particularly well suited for this still. With jacketed condensers, a circulating and cooling water supply runs between the jacket and the core. This condenses the liquids contained in the hot vapors coming from the column and going through the core.

Here's a sketch of what the insides of the condenser look like:

Simple as it might seem, there are a lot of considerations behind making a proper condenser for the kind of column we want to build.

Most low capacity distillation devices use a small capacity condenser. This is because they are designed for only one purpose: to drop the temperature of the distillation vapor to the point where the liquid separates out of the vapor. That usually does not require a great deal of cooling. Pot stills sometimes just use a coil of tubing that cools the vapor by just exposing it to the surrounding air temperature.

But keep in mind we are building a reflux still. That is a more sophisticated design. In the course of its operation, the reflux still produces a much higher quality of distillate than the pot stills because it effectively re-distills the mixture many times before it is drawn off from the still. That of course, requires much more cooling and much better temperature control than the simpler pot stills.

So, to accommodate these needs, we've designed this still with a much larger cooling capacity incorporated into the condenser. We've done that because we need not only the cooling required to condense the distillate vapors, but also to carefully regulate and control the temperatures inside the reflux tower.

To properly utilize the extra cooling capacity, we've made the water supply and drain lines from V2" copper pipe and run these cooling lines through the reflux column as part of the normal cooling circulation. The primary purpose of these lines is to control the amount of re-distillation (reflux) that occurs inside of the column.

In the sketch shown below you can see that the input cooling water is circulated first through the bottom of the column, then through the condenser, and finally back through the top of the column again.

The rather large surface area of the copper jacket of this condenser acts as a radiator. It dissipates the heat conducted both by the lower input cooling pipe and the heat absorbed from the column vapors by the water as it passes through the column on its way to the condenser.

Those are the reasons why the big, jacketed condenser we are going to build for this job is better. Its also happens to be easier to fabricate and more efficient than those condensers which use a coiled tube contained within the distillate output pipe.

The first step in building the condenser is to fabricate the core assembly.

The Condenser Core

Here's a drawing of what we want to make first. It's the condenser core. It's made from only three pieces:

To make the core you begin by soldering together a IV2" X 1" reducing coupling to a 23" length of 1" pipe. Be sure to clean the fittings and pipe with sandpaper or a stiff wire brush so it shines. Then brush on some flux to both pieces, and use lead-free solder. When you heat the joint enough with a torch, the solder will be sucked up into the joint. While the solder is still runny looking and shiny, wipe the joint with a clean rag. Makes a nice finish on the joint. Then solder a 1" X V2" reducing coupling on the other end in the same way. When you get done, it'll look like this:

The Condenser Jacket

The next step is to build a jacket that fits closely around the core. That will allow a thin, fast moving, layer of water with a lot of surface area to circulate around the core, and quickly absorb the heat. In turn, it also allows the condensation rate (both internal and external) to react as quickly as possible to changes in the water flow.

Since the column output is made of 1 V2" piping, we have to reduce this down to 1" piping for the core (above), and then make the jacket out of 1 V2" pipe. That will leave a W space surrounding the core for the water to circulate. To do this, we have to do some strange things to the end caps of the jacket, so that it will match the underlying core plumbing. Here's what's involved:

One cap has a 1 1/8" hole drilled in the end, the other cap, a 5/8" hole. The hardest part is to cut the right size holes in the caps so they will fit nicely with the core.

When the caps are done, you have to cut two nipples of 1 V2" pipe each 2 V2" long, and a piece 23 V2" long for the main jacket. When you assemble the jacket, the V2" reducing tee outlets should be 18 V2" on center. This is not a critical length, but later on you will see that it is important to insure that the cooling tube holes in the reflux column match this dimension.

The more important dimension is the overall jacket length. When the core is placed inside the assembly, it should fit snugly at both the top and bottom caps. You can adjust the length of either one of the nipple fittings (before you solder them) to make any fine adjustments.

Now you can complete the assembly by putting the core assembly through the holes in the jacket end caps, making sure the Tee's are centered along the length, and soldering all the joints. The core and jacket should look like this just before putting them together.

Continue reading here: Building the Reflux Column

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Readers' Questions

Anya
Is it possible to make a condenser coil with1/2 x 10' type m copper tubing?

13 days ago
- Reply

Yes, it is possible to make a condenser coil with 1/2" x 10' Type M copper tubing. Type M copper tubing is commonly used for residential plumbing applications and it can also be used in the construction of a condenser coil. However, it is important to note that the design and dimensions of the condenser coil should be determined based on the specific requirements of the system it will be used in.

Sandy Burns
Can a cpvc pipe condenser be used on alcohol still?

13 days ago
- Reply

Yes, a CPVC (Chlorinated Polyvinyl Chloride) pipe condenser can be used on an alcohol still. CPVC is a type of plastic pipe that is resistant to heat and can handle high temperatures, making it suitable for use in distillation processes. Just ensure that the CPVC pipe and any associated fittings used in constructing the condenser are rated for the temperature and pressure conditions of your specific still setup. It is always advisable to consult with the manufacturer's recommendations or seek guidance from a professional to ensure safe and efficient operation.

dieter
How to build a mechanicaly stirred reaktionsetup with reflux condenser?

6 months ago
- Reply

To build a mechanically stirred reaction setup with a reflux condenser, you will need the following equipment and materials: 1. Reaction vessel: This is the container where the reaction will take place. It should be made of a material compatible with the reactants and the conditions of the reaction. 2. Stirrer: A mechanical stirrer is required to create agitation and promote mixing during the reaction. It can be a magnetic stirrer or a mechanical overhead stirrer. 3. Reflux condenser: This is a condenser that is used to cool and condense vapors produced during the reaction. It prevents volatile reactants or products from escaping the reaction vessel and ensures they remain in the system. 4. Heating source: Depending on the specific reaction, you may need a heating mantle or a hot plate to control the temperature of the reaction. 5. Cooling source: A cold water source, such as a water circulator or a chiller, is required to cool the reflux condenser and condense the vapors. 6. Thermometer: A thermometer is needed to monitor and control the temperature of the reaction. 7. Thermocouple/temperature controller: A thermocouple or temperature controller can be used to ensure accurate temperature control during the reaction. 8. Safety equipment: Safety goggles, gloves, and a lab coat should be worn when working with chemicals to protect yourself from potential hazards. Now, here's a step-by-step guide to set up the reaction setup:
Set up the reaction vessel on a stable surface, ensuring it is properly clamped if necessary.

Connect the reflux condenser to the top of the reaction vessel. Make sure it fits securely with appropriate connectors and clamps.

Connect the cooling source to the reflux condenser. Attach the water inlet and outlet hoses so that the cooling water can circulate through the condenser.

Insert the stirrer into the reaction vessel. If using a magnetic stirrer, place a stir bar inside the vessel and position it in the center. Alternatively, attach the mechanical overhead stirrer to the reaction vessel.

Connect the stirrer to the appropriate power source. For a magnetic stirrer, place the magnetic stirrer plate underneath the vessel and adjust the speed and direction of the stirring as required. If using a mechanical overhead stirrer, connect it to a power source and adjust the speed accordingly.

Ensure that all connections are tight and secure.

Set up the heating source underneath the reaction vessel if required, and connect it to the appropriate power source.

Attach a thermometer or a thermocouple to monitor the reaction temperature. Connect it to a temperature controller if desired.

Add the reactants to the reaction vessel, ensuring all safety precautions are followed.

Start the stirrer and adjust the speed as needed for efficient mixing.

Turn on the cooling source to cool the reflux condenser. Adjust the flow rate of the cooling water to maintain an appropriate condensation level.

If using a heating source, set the desired reaction temperature and monitor it with the thermometer or temperature controller.

Conduct the reaction, monitoring the progress and making any necessary adjustments during the process.
Remember to follow good laboratory practices, adhere to safety guidelines, and be familiar with the specific requirements and precautions for the chemicals and reaction you are conducting.

natsnet
Can anything coat the inside of pvc pipe to use in distilling?

8 months ago
- Reply

Yes, it is possible to coat the interior of a PVC pipe for use in distilling. Most commonly, a polyurethane-based coating is applied. This type of coating is highly durable and provides a protective barrier against corrosion. It is important to ensure that any coating used is safe for use with water and other drinks that may be distilled.

Leonie
How to build a worm condenser?

10 months ago
- Reply

A worm condenser is a type of cooling apparatus used to remove excess heat from air or other gases in industrial and manufacturing processes. To build a worm condenser, you will need a sheet of metal, some screws, a drill, and a tube-shaped piece of metal such as copper.
Start by drilling holes in the sheet of metal and the tube-shaped piece of metal. The holes should be evenly spaced and of the same size.

Place the tube-shaped piece of metal in the center of the sheet of metal.

Secure the tube-shaped piece of metal to the sheet of metal using the screws.

The tube-shaped piece of metal should now be secured to the sheet of metal. The holes in both pieces should align perfectly to form a continuous loop.

Attach one end of the tube-shaped piece of metal to an air inlet and the other end to an air outlet.

Connect the air inlet and the air outlet to a fan or blower to complete the condenser.
The completed worm condenser should now be able to efficiently remove excess heat from air or other gases in industrial and manufacturing processes.

regolo
How to build an efficient distillation condenser using pvc jacket and copper pipe?

1 year ago
- Reply

Begin by cutting two pieces of copper pipe to your desired lengths. Use a hacksaw to make the cuts. The two pieces should be equal in length.

Attach the pieces of copper pipe to the PVC jacket using a pipe thread sealant. Use a wrench to tighten the joints and make sure they are secure.

Secure the copper pipe to the PVC jacket by screwing the copper pipe securely into place. Use a wrench to tighten the connections.

Place a rubber washer over the copper pipe at each end. This will help create an air-tight seal between the copper pipe and the PVC jacket.

Place a piece of rubber hose over the copper pipe at each end. This will act as an insulation layer, making sure that the heat does not escape from the distillation condenser.

Attach the other end of each piece of rubber hose to the PVC jacket. Use a clamp to secure the hose to the jacket.

Insert the copper pipe into the PVC jacket. Make sure that the pipes are properly aligned and that they are positioned tightly in the PVC jacket.

Attach the cooling tubing to the copper pipe at each end. Make sure that the connections are secure and that the tubes are properly aligned.

Connect the water lines to the cooling tubes. Make sure that the connections are secure and that there are no leaks.

Turn on the water supply and allow the water to run through the copper pipe and cooling tubes. This will create a coolant flow that will help to condense the steam and create the distillate.

Monitor the condenser and adjust the water flow as needed. This will help ensure that the condenser is running efficiently and effectively.

Mike
How to build graham coil condenser?

1 year ago
- Reply

Gather the necessary materials. You will need a roll of insulated copper wire, such as magnet wire, a plastic or cardboard tube, a wooden or plastic base, and some adhesive.

Cut two equal lengths of the insulated copper wire, each slightly shorter than the length of the tube.

Wrap one of the wires around the top of the tube and secure it in place using some adhesive.

Repeat this process with the other wire, wrapping it around the bottom of the tube.

Connect the two wires to the base with the adhesive.

Coil the wires around the tube, taking care to ensure that each loop is secure and evenly spaced.

Secure the coil in place with some adhesive and let dry before use.

JAMIE WRIGHT
How big shoyuld a still condenser be?

1 year ago
- Reply

The size of a still condenser will depend on the type of still you are using and the amount of alcohol you are trying to produce. Generally, it should be big enough to accommodate the capacity of your still as well as the amount of cooling water you will be using. In addition, it should be able to handle the pressure created by vaporization during distillation.

Wilibald Puddifoot
How to build a water condenser?

1 year ago
- Reply

Gather the required materials. You'll need a drill, a battery-powered pump, an external thermostat, a water storage tank, a container (such as a trash can), two rubber stoppers, PVC piping, two buckets, an electric heater, and a source of water.

Drill two holes in the side of the container, one near the bottom and one near the top. Fit the PVC pipes into the respective holes.

Place the water storage tank near the top hole and fit the PVC pipe into the hole. Make sure it is secure.

Insert the rubber stoppers into the bottom hole to create a watertight fit.

Connect the battery-powered pump to the top PVC pipe and run the other end of the tubing into the water storage tank.

Place the electric heater into the bottom of the container and connect it to the thermostat.

Place the two buckets into the container, one inside the other.

Fill the container with water and turn on the pump. This will cause the water to be pumped up to the top of the container and gradually condense in the storage tank.

Monitor the temperature of the thermometer and adjust the thermostat accordingly to ensure the water is being properly condensed.

After the water has been sufficiently condensed, turn off the pump and remove the condensed water from the storage tank for use.

mewael
How to construct a condenser?

1 year ago
- Reply

Prepare the components for the condenser. You will need copper tubing, copper fittings, a copper cap, and a copper flaring tool.

Measure and cut the copper tubing to the desired length. Make sure the ends are clean and free of burrs.

Form the copper tube into a U-shape with the flaring tool. This will create a bend in the tube.

Connect the two ends of the condenser using the copper fittings. Make sure the fittings are securely tightened.

Place the copper cap over the open end of the condenser. This will help to contain the coolant that will be used to cool the condenser.

Test the condenser to make sure it is functioning properly.

HABEN
How to make condenser at home?

1 year ago
- Reply

Making a condenser at home is a challenging task, as you need some advanced tools and skills to complete the job. However, here are some steps to guide you in creating a simple condenser at home:
Gather Materials – You will need copper tubing, copper fittings, a soldering iron and solder, plumber’s tape, and a drill with drill bits.

Cut the Tubes – First, measure and cut the copper tubes and fittings to the desired length and width.

Solder the Joints – Next, you need to solder the joints of the copper tubes and fittings, using your soldering iron and solder.

Wrap the Connections – Use the plumber’s tape to wrap the soldered joints to seal the connections.

Drill the Connections – Use the drill to make a hole in the center of each connection.

Insert the Connectors – Insert the connectors into the drilled holes and tighten with a wrench.

Attach the Connections – Join the connections together with nuts and bolts.

Test the Condenser – Finally, test the condenser to make sure it is working correctly.

Almaz
How to build a condenser for distillation?

1 year ago
- Reply

Create the condenser. You will need a long, heat-resistant tube, the same diameter as the end of the boiling flask. This can be made of glass or metal.

Attach the condenser to the boiling flask. Use a standard ground glass joint. It should fit securely and should not leak.

Connect the condenser to a cooling system. This can be as simple as running cold water through a hose that wraps around the condenser. A more complex system might include a water pump, reservoir, and cold plate.

Connect the other end of the condenser to a collection flask. This can be a regular glass beaker.

Prepare the boiling flask for distillation. Fill it with the liquid to be distilled, and attach it to a heat source.

Turn on the heat source and the cooling system. The liquid in the boiling flask will begin to evaporate and condense inside the condenser tube. The condensed liquid will drip down into the collection flask.

Monitor the process as distillation continues. When the desired amount of liquid has been collected, turn off the heat and cooling systems.

Unscrew the ground glass joint that connects the condenser and boiling flask, and remove the condenser tube.

selma
How to wrap a cooling coil for a reflux still?

1 year ago
- Reply

Start by cutting the copper tubing to the desired length. Make sure to account for the water-cooled copper coil added length when calculating the total coil length. Use a tube bender to bend the copper tubing into a coil shape. Make sure the coil fits snugly in the collection vessel.

Secure the copper tubing coil in place using strong adhesive or clamps. Make sure to secure the cooling coil tightly so it does not move around when in use.

Feed the cooling water into the inlet of the cooling coil by using a water source such as a hose or a bucket. Adjust the water flow to a low trickle, as you want to make sure enough water passes through the copper coil to cool down the rising vapors.

Once the cooling water is on, fit the collection vessel with the reflux condenser. The condenser goes on the top of the vessel, with the cooling water outlet of the condenser going into the coil.

Place the bottom of the still vessel in the collection vessel. This should be done before turning the cooling water on. Be sure to turn off the cooling water before removing the still from the collection vessel.

Lastly, connect the cooling water outlet of the cooling coil to a drainpipe or bucket so the cooled water can be safely discarded.

CHRISTOPHER
How to Build an Alcohol Distillation Device?

1 year ago
- Reply

Gather the necessary materials: a pot for boiling water, some type of heat source (like a propane burner), 2-4 feet of copper tubing, 2 funnels, 2 rubber stoppers, and a collection vessel.

Create a coil of the copper tubing by wrapping it around your pot and securing it with wire or zip ties.

Place the pot and coil on your heat source and fill it with water.

Place the funnels in the stoppers and insert them into the ends of the copper tubing.

Add the alcohol to the pot and begin to heat it until vapor rises.

The vapor that is created will travel through the copper coil and collect in the funnels.

Collect the condensate in your collection vessel.

Discard the remaining liquid in the pot and allow the collected condensate to cool before using.

sini
Can condenser be made larger than the column on a still?

1 year ago
- Reply

Yes, a condenser can be made larger than the column on a still. However, it is generally not recommended because larger condensers increase the risk of the still producing off-flavors and stripping the distillate of its flavor. When the column of the still is larger than the condenser, it allows for more refluxing and better heat control, resulting in a higher-quality distillate.

dennis
How to build distiller condenser?

1 year ago
- Reply

Start by assembling the parts for the condenser. Gather the condenser itself, a heat-resistant connector, a glycerin-filled thermometer, and a distillation head or distillation adaptor.

Attach the distillation head or distillation adaptor to the condenser using a heat-resistant connection.

Insert the glycerin-filled thermometer into the distillation head or adaptor. Make sure the thermometer is secure and that the readings are accurate.

Place the condenser onto the distillation flask and make sure it is secured tightly.

Connect the condenser to a cold water supply and turn on the water.

Let the water run through the condenser until the temperature readings are stable.

Adjust the temperature as needed and monitor the thermometer for accuracy.

Once the temperature is stable and readings are accurate, the condenser is ready for use.

Teija
How to build a cooling jacketed condenser?

1 year ago
- Reply

First, gather the necessary materials for your cooling jacketed condenser, such as copper piping, copper tubing, compression fitting, a cooling jacket, water supply pipe, and disconnect valve.

Next, measure and cut the copper pipes to the desired length and shape, using a skill saw or pipe cutter.

Attach the copper pipes to the cooling jacket with soldering or compression fittings.

Install the water supply pipe to the cooling jacket, making sure to leave enough slack to make connecting and disconnecting easier.

Connect the water supply pipe to the disconnect valve and ensure that it is properly sealed.

Attach the copper tubing to the cooling jacket and the condenser using compression fittings.

Test your cooling jacketed condenser by turning on the water supply and making sure that there are no leaks.

Finally, check the temperature of the condenser to make sure that it is being cooled properly.

yorda
Can cooling coils in reflux column control distillation?

1 year ago
- Reply

Yes, cooling coils in reflux columns can be used to control the distillation process. Cooling coils are used to control the temperature in the reflux column, which can optimize the distillation process by ensuring that the vapors being condensed are of the correct temperature. Cooling coils also help to avoid any fluctuations in the temperature in the reflux column which could cause fluctuations in the distillation process.

jamila
How to make a jacketed condenser?

1 year ago
- Reply

Gather your materials. You will need two length of rigid copper or stainless steel tubing or two lengths of soft annealed copper tubing, two end caps, two gaskets, two stainless steel or galvanized pieces of sheet metal, and two sealing rings or gaskets.

Cut the two lengths of tubing to the desired length.

Place one end cap onto one piece of tubing.

Place one gasket onto the other piece of tubing and insert the tubing into the end cap.

Bolt the two pieces of tubing together with the nuts and bolts provided.

Place the two pieces of sheet metal over the two lengths of tubing.

Place the two gaskets over the two lengths of tubing and secure them with the nuts and bolts provided.

Place the two sealing rings or gaskets on top of the two pieces of sheet metal and secure them with the nuts and bolts provided.

Connect the two lengths of tubing to the end caps and tighten them with the nuts and bolts provided.

Your jacketed condenser is now complete!

Building The Condenser

The Condenser Jacket

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