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We are trying to design a classic copper pot still (close to classic copper alembic still) based on SD 100gal/380L boiler. It is stainless steel kettle, but copper kettle is more expensive for us, right now. Use case of this still is to make a 1st and 2nd run to distill flavored spirit: mostly brandy and grappa, whisky in nearest future, potentially rum and tequila). As I said, classic alembic, no plated units.
Still will be feed by 4 heating elements, 5000 - 5500 watts each, 2 heating elements will be directly connected to electrical panel (through outlets) to 240V/30A breaker, and 2 remaining heating elements will be connected through SSR based controller. These heating elements will be collected to 125A US electrical panel.
General design is (from boiler to parrot) is to have the onion head, that is 25" in diameter with 8" TC on top and bottom -> copper column or cone (I will describe it later) -> reducer to 2" with temp gauge -> 2" "U" elbow or set of 90 degrees elbows / pipe -> reducer from 2" to 4" -> 4" wide copper based shotgun condenser with maximum amounts of 1/2" pipes inside, 4 fts tall -> spirit collector / base of 4" condenser-> parrot made from 3/4" -1" pipes for better flow.
I saw a post of @CothermanDistilling (8" Crystal Dragon R&D...) where he described his setup with 4" wide condenser, 48" tall. The only unknown part to me would be collector unit with 4" TC on top and bottom, similar to one that is on attached pictures where I rounded it red. Just with the difference to 8" wide on the picture vs. 4" to what we need. So, we guess, that it would be easier is to have 2" to 4" copper or SS reducer -> 48" tall 4" wide copper shotgun condenser -> 4" wide copper or SS spirit collector -> 4" wide piece of empty pipe with 4" TC on both sides (SS or copper) -> standard 1/2 or 1/6 barrels SS keg with 4" TC welded on top as a massive base (no spirit or similar usage there, just big and massive SS tank solid enough to act as a base)
Column or Cone:
There is quite thoughts. Original idea (1) was to make just straight 8" wide pipe on top of the onion head, with 8" to 2" reducer with temp gauge. 24" tall. Solution is reasonably easy to implement (just 8" to 2" reducer might be a problem). Alternative idea (2) is to use a one piece cone 8" to 6", 24" tall as better emulation of classic alembic forms. Any comments of what would be better in this case?
All copper thickness should be 1.0 - 3mm for durability.
The real question if 4 x 5000/5500 watts would be enough to heat 100 gallons of wash, SS boiler, the onion head, 8" copper column/cone, 2" pipe to condenser? And would it have any benefits of using 8"-to-6" cone over 8" column?
Additionally, do you think, that having 24" tall column would be enough to provide a good contact to copper / have enough "copper" to make good flavored spirit? Or, it is better to make it taller, like 36" or even 48" ?
Based on post of @CothermanDistilling, I think that 4" wide / 48" tall shotgun condenser should be enough, plus I can obviously control cold water flow.
Any other comments, inputs, suggestions?