The bigger the better. I thought my 16.25 would be plenty. Well, guess what has two thumbs and still has boil overs? This guy!! So, go big or go home. I would not attempt it with less than 15 gallon, and a good spray bottle.
I just bought a 20 gallon kettle. It’ll have its maiden voyage in a few days. I figured if I want to make 10 gallons, I’ll need to brew 12 to compensate for the sludge in the bottom of the kettle. If I want 12 gallons, I’ll have to sparge off close to 14 gallons. A 15 gallon kettle just won’t cut it. The 20 gallon kettle was only $30 more at NB. I figured it was a no-brainer.
Blichmann also recommends twice the capacity. With boiloff, your starting volume might be 12 gallons and 3 gallons is usually only 6 inches of headspace. Not much.
I use a 14 gallon kettle and it is pretty close to the top when I finish sparging/lautering. I recommend larger ifd you can, but the 14 gallon works, you just have to feather the flame. That said I always targeted 12 gallons so that I got 5 by the time I was kegging.
If you are careful you can bring the wort to a boil literally an inch from the surface and not have a boil over. You don’t have to have the flame turned up full blast all the way through the boil - a gentle boil is all you need.
I never thought it was that difficult to do 10 gal batches in a 15-gal kettle with 60-minute boils. Add some hops before the boil to avoid a boilover. That is a good tip from Greg Noonan’s Brewing Lager Beer. 15 gal might be small if you are doing 90-minute boils and you want to avoid topping up.
This is where I had my problems. 90 minute boils with BoPils malt where I needed a good rolling boil to get rid of the DMS. 60 minute pale ale/2 row boils are not a major problem, but you still have to be careful.
I use a 20 gallon kettle and what is nice is heating all my liquor at once. I heat the strike water to mash temp, drain off to my mash tun and leave the rest to heat to sparge temps and then drain to a 10 gallon cooler to keep it at sparge temps. Saves a little time heating all the liquor at once.
Guess it kinda sounded like that, huh? :) What I was trying to say is that it doesn’t seem to prevent boilovers any more than controlling the flame does. If I didn’t take other steps, I’d have boilovers, even with hops in 7 gal. of wort in a 15 gal. kettle.
I noticed that the wort is less prone to boil over when hops are added before the boil starts. It doesn’t prevent boil-overs, but it my experience it makes it easier to control them.