Energy-efficient Baijiu distillation via novel floating coil heat exchanger and non-powered double cylinder ice condenser: simulation and experimental validation

Abstract The quality of Baijiu depends on the performance of the distillation process. Traditional distillation apparatus exhibits several drawbacks, including uneven heating and condensation, imprecise temperature control, and high energy consumption, which necessitate optimization. This study aims to improve quality, aroma, cost-effectiveness, and efficiency. Initially, a simulation analysis of flow and temperature distribution in traditional distillation is conducted to identify deficiencies in the equipment. Subsequently, the design of two critical components, the heat exchanger and condenser, is optimized through a combination of theoretical design and computational fluid dynamics (CFD) simulation. Finally, a comparative Baijiu brewing test is performed to validate the effectiveness of the optimized design. Results indicate that the use of the optimized distillation equipment enhances efficiency by 19 % and reduces unit energy consumption by 25 %. Furthermore, it increases the concentration of flavor compounds in Baijiu while decreasing harmful fusel alcohols, resulting in a richer and healthier Baijiu product.