I broke down and bought two more T-unions, some valves, more 1/4" line, and a spool of 6" wide coppe…

[Thumpin455]

I broke down and bought two more T-unions, some valves, more 1/4" line, and a spool of 6" wide copper sheet. I was having difficulty finding 3" tubing for the condenser so I decided to build one from sheet. It is more effort, but the price was right considering I can build a bunch of other stuff from the sheet, and really I only needed an 11" long piece of the 10' roll. Plenty left over for more projects. So now I will have two stills, and I might try one with plates rather than packing, it may not be worth your time to do it that way, but since I have the time why not?

Additionally there is now 200lbs of corn in the inventory so we can make malt rather than buy enzymes, and I found a 1/2hp food disposal on clearance for $40. Perhaps I should have bought two. So most of the processing equipment is in place, malt will be sprouting in a few days, and I just need to decide what direction to go for heat, until the biogas plant becomes a reality. The cost of the flexible plastic water pipe is the holdup on that project, until then maybe I can break down and use a small bottle of propane to get started.

Rather than build another boiler from scratch, or modify a 55 gallon drum, a copper fitting that will screw into the large bung on the barrel is now the base for the still. That makes it easier to use any drum for distillation, be it a 55 or a 20 gallon with no changes needed other than cleaning it. The plan is to convert starch and ferment in another container, then filter the solids from the mash prior to going in the still. That should keep the cleaning to a minimum, as well as sticky residue form direct heat that I am currently forced to use.

These are the parts needed, some I needed to buy in bulk, others in singles.


This is the almost complete still, it needs the cooling lines and reflux tube added, as well as the output valve. This one is rough, the second one will look nicer, I don't worry about aesthetics when doing the first build. Excuse the mess behind the Cougar, there are two cars getting rebuilt in the shop, and parts for many others stashed around the place.



The first few runs will probably be sugar only to simplify the process, then some cattails and potatoes will be next.

[Thumpin455]

A very "interesting" summer in 2009 forced me to postpone almost the entire ethanol/biogas project. Instead I managed to get some automotive projects out of the way that didnt require much cash to complete. It also allowed the cattails to grow and I have leads on other patches I can have if I clean them out. I have some laborers to help this fall as well, so now the project can move forward again.

First order of business is the biogas plant. There is a stack of tubing ready to go into the compost, and the radiators are stashed in the shop waiting to be connected to a heat source. Almost all the pieces are in place waiting to be assembled, and the wood chips are available so there is no time like now to get it done. With the heat and methane from the compost I can be productive through the winter months. It will also provide the resources I need to control temps to make fuel. If it works well enough we will probably set up another system in the house for cooking gas and heat, that will require much less firewood each winter. Using less firewood means more resources available for other projects instead of heating the house.

Im still figuring out the boiler, unsure if I will use a heat jacket or direct heat. The jacket idea would allow me to utilize the hot water we will be making without losing it and allow better control of heat. The drawback is more complexity and more things that can go wrong. Today I am clearing the shop to install the heat system, and will be taking pictures of the install as I go. The idea has generated a ton of interest up here, and with good reason. We have plenty of wood chips and long winters, while we live in a rather economically depressed region. So the pressure is on to prove the system will work this year and I have a certain individual who feels it will never work. One of the biggest motivators for me has always been someone telling me that I cant do it, or I will never make it work. Even if it doesnt work, I still learn from the doing so either way I win. Most of the people who say that are not the type to actually do something or try to make an idea work. So its rare that I have to admit defeat. :)

[Thumpin455]

I am still alive, and not giving up, just unable to get much done. Other items and issues are forcing their way into the list, and they are at the top of the list. I wish I could do more with my project, but it has to wait, I dont have a choice in the matter.

[Thumpin455]

Since the snow is gone now we are planning to pull some up and see what we can do with them. Until this week they were buried under 3' - 8' of white stuff and ice. I dont want to pull an entire patch, but if I can get a pickup bed load or so I can do some testing. That is provided the biogas plant comes to be in May and I figure out some aspects of the boiler.

We did some small batches with a 5 gallon bucket of rhizomes last year, but they were mashed by hand and it was a long process. The old still was a small one that made less than a gallon per batch, more of a learning item than anything. This year we will have two 2" columns, and run multiple 55 gallon drums for boilers. As soon as I get some results believe me I will post them. :)

[Ron Fisher]

have you done any cattail batches yet? I am interested in your out comes since I am looking to do that also...so far I am still building my 6" plant my still is finished but the boiler is not...

[Thumpin455]

The corn is going to be used for malt, it will probably find its way through the disposal for prep. Save on some enzymes that way. Until I get the boiler figured out my only option is to use the 20 ga barrel holding the still. I have another 55 gal with no lid, so it could get a couple electric heating elements, filled with water, and the 20 anchored inside the 55.

Since I don't have reliable cheap heat in the shop, I would have to do conversion and fermentation inside the house, so I can control temps. That means getting creative with the wood burner that heats the house. Of course spring/summer eliminates most of those concerns, and winter is really a difficult time to make alcohol here anyway.

When the cattails get the opportunity to become fuel, they will probably get cooked first for a bit to soften them, run through the disposal, then with some malt added to do the conversion. Cattails can be a bit tough, like tree branches, and we don't want to ruin the disposal on the first run. Still need a few more things before I can run more than a gallon at a time.

[Craig Fazakerly]

Looks nice, I bet you can't wait to fire it up. Do you have a grain mill for the corn? Or is that what the disposal is for? I plan to start grinding this weekend.