Continuous tunnel batch washer apparatus

Abstract

An improved tunnel washer apparatus ( 20 ) is disclosed that includes a “ratio metric” water reuse system that features four water loops. The water loops include fresh water ( 24 ), reuse water ( 51 ), rinse water ( 49 ), and treated water ( 50 ). The tunnel washer ( 20 ) has five stages that include wet out ( 13 ), first wash zone ( 14 ), second wash zone ( 15 ), main rinse zone ( 16 ), and fine rinse/finishing zone ( 17 ). The water loops are designed to minimize the consumption of fresh water by blending the appropriate quantity of the four types of water. The blending formulation may vary based on the type of goods (for example linen) in the tunnel stage and the dynamic quality of each type of water.

1 . A continuous tunnel batch washer apparatus, comprising: 
 a) an elongated outer housing having opposing ends, an inlet at one of said ends and an outlet at the other of said ends, the housing having a water containing portion;    b) a plurality of lateral walls dividing at least a portion of the housing into a plurality of cells;    c) the housing containing a plurality of drums, each being rotatably supported within the water containing portion of the frame, each having a drum inlet for enabling goods to be washed to enter the drum and a drum outlet for enabling the goods to exit the drum, and at least some of the cells having drums therein;    d) a fresh water header for supplying water to the water containing portion of the housing;    e) a rinse water flow line that receives water that has been discharged from the water containing portion of the housing;    f) a treated water flow line that receives water that has been discharged from the water containing portion of the housing;    g) means for removing solid waste material from water flowing in at least one of the flow lines that receives water that has been discharged from the water containing portion of the housing and for transmitting such treated water to the treated water flow line; and    h) wherein water flowing in the treated water flow line supplies water to the wash zone.    
     
     
         2 . The continuous tunnel batch washer apparatus of  claim 1  wherein water flowing in the rinse water flow line supplies water to the wash zone.  
     
     
         3 . The continuous tunnel batch washer apparatus of  claim 1  wherein the water flowing in the treated water flow line is flowing a high flow rate that is higher than the flow rate of water flowing in the fresh water header.  
     
     
         4 . The continuous tunnel batch washer apparatus of  claim 1  wherein the water flowing in the treated water flow line is flowing a high flow rate that is higher than the flow rate of water flowing in the rinse flow line.  
     
     
         5 . The continuous tunnel batch washer apparatus of  claim 1  further comprising a turbidity meter for monitoring the turbidity of water that has been discharged from the water containing portion of the housing.  
     
     
         6 . The continuous tunnel batch washer apparatus of  claim 1  further comprising a plurality of valves that automatically meter the flow of water from the treated water and rinse water to the cells.  
     
     
         7 . The continuous tunnel batch washer apparatus of  claim 1  further comprising a plurality of valves that automatically meter the flow of water from the treated water and fresh water to the cells.  
     
     
         8 . The continuous tunnel batch washer apparatus of  claim 1  further comprising a plurality of valves that automatically meter the flow of water from the rinse water and fresh water to the cells.  
     
     
         9 . The continuous tunnel batch washer apparatus of  claim 1  wherein the means for removing solid waste includes a centrifugal separator.  
     
     
         10 . The continuous tunnel batch washer apparatus of  claim 1  further comprising means for injecting ozone into the treated water flow line.  
     
     
         11 . A continuous tunnel batch washer apparatus, comprising: 
 a) an elongated outer housing having opposing ends, a hopper inlet at one of said ends and an outlet at the other of said ends, the housing having a water containing portion;    b) a plurality of lateral walls dividing at least a portion of the housing into a plurality of cells;    c) the housing containing a plurality of drums, each being rotatably supported within the water containing portion of the frame, each having a drum inlet for enabling goods to be washed to enter the drum and a drum outlet for enabling the goods to exit the drum, and at least some of the cells having drums therein;    d) at least a plurality of the drums having inclined chutes that transfer goods to be washed from one cell to another adjacent cell when the drums are rotated a selected angular amount;    e) a fresh water header for supplying water to the water containing portion of the housing;    f) a rinse water flow line that receives water that has been discharged from the water containing portion of the housing;    g) a treated water flow line that receives water that has been discharged from the water containing portion of the housing;    h) means for removing solid waste material from water flowing in at least one of the flow lines that receives water that has been discharged from the water containing portion of the housing and for transmitting such treated water to the treated water flow line; and    i) wherein water flowing in the treated water flow line supplies water to the wash zone.    
     
     
         12 . A continuous tunnel batch washer apparatus, comprising: 
 a) an elongated outer housing having opposing ends, an inlet at one of said ends and an outlet at the other of said ends, the housing having a water containing portion;    b) a plurality of lateral walls dividing at least a portion of the housing into a plurality of cells;    c) the housing containing a plurality of drums, each being rotatably supported within the water containing portion of the frame, each having a drum inlet for enabling goods to be washed to enter the drum and a drum outlet for enabling the goods to exit the drum, and at least some of the cells having drums therein;    d) a fresh water header for supplying water to the water containing portion of the housing;    e) a rinse water flow line that receives water that has been discharged from the water containing portion of the housing;    f) a treated water flow line that receives water that has been discharged from the water containing portion of the housing, the treated water flow line having a flow rate that is greater than the flow rates in the fresh water header or rinse water flow line;    g) a separator that enables solid waste material to be removed from water flowing in at least one of the flow lines that receives water that has been discharged from the water containing portion of the housing and for transmitting such treated water to the treated water flow line; and    h) wherein water flowing in the treated water flow line supplies at least part of the water to the wash zone.    
     
     
         13 . The continuous tunnel batch washer apparatus of  claim 12  wherein water flowing in the rinse water flow line supplies water to the wash zone.  
     
     
         14 . The continuous tunnel batch washer apparatus of  claim 12  wherein the water flowing in the treated water flow line is flowing a much higher flow rate than the flow rate of water flowing in the fresh water header.  
     
     
         15 . The continuous tunnel batch washer apparatus of  claim 12  wherein the water flowing in the treated water flow line is flowing a much higher flow rate than the flow rate of water flowing in the rinse flow line.  
     
     
         16 . The continuous tunnel batch washer apparatus of  claim 12  further comprising a turbidity meter for monitoring the turbidity of water that has been discharged from the water containing portion of the housing.  
     
     
         17 . The continuous tunnel batch washer apparatus of  claim 12  further comprising a plurality of valves that automatically meter the flow of water from the treated water and rinse water to the cells.  
     
     
         18 . The continuous tunnel batch washer apparatus of  claim 12  further comprising a plurality of valves that automatically meter the flow of water from the treated water and fresh water to the cells.  
     
     
         19 . The continuous tunnel batch washer apparatus of  claim 12  further comprising a plurality of valves that automatically meter the flow of water from the rinse water and fresh water to the cells.  
     
     
         20 . The continuous tunnel batch washer apparatus of  claim 12  wherein the means for removing solid waste includes a centrifugal separator.  
     
     
         21 . The continuous tunnel batch washer apparatus of  claim 12  further comprising means for injecting ozone into the treated water flow line.  
     
     
         22 . A continuous tunnel batch washer apparatus, comprising: 
 a) an elongated outer housing having opposing ends, a hopper inlet at one of said ends and an outlet at the other of said ends, the housing having a water containing portion;    b) a plurality of lateral walls dividing at least a portion of the housing into a plurality of cells;    c) the housing containing a plurality of drums, each being rotatably supported within the water containing portion of the frame, each having a drum inlet for enabling goods to be washed to enter the drum and a drum outlet for enabling the goods to exit the drum, and at least some of the cells having drums therein;    d) at least a plurality of the drums having inclined chutes that transfer goods to be washed from one cell to another adjacent cell when the drums are rotated a selected angular amount;    e) a fresh water header for supplying water to the water containing portion of the housing;    f) a rinse water flow line that receives water that has been discharged from the water containing portion of the housing;    g) a treated water flow line that receives water that has been discharged from the water containing portion of the housing;    h) means for removing solid waste material from water flowing in at least one of the flow lines that receives water that has been discharged from the water containing portion of the housing and for transmitting such treated water to the treated water flow line; and    i) wherein water flowing in the treated water flow line flows at a rate that is at least twice as high as the flow rate of one of the other flow lines.    
     
     
         23 . A continuous tunnel batch washer apparatus, comprising: 
 a) an elongated outer housing having opposing ends, an inlet at one of said ends and an outlet at the other of said ends, the housing having a water containing portion;    b) a plurality of lateral walls dividing at least a portion of the housing into a plurality of cells, the cells being grouped into a first wash zone group of one or more cells, a second wash zone of one or more cells, a main rinse zone of one or more cells and a fine rinse zone of one or more cells;    c) the housing containing a plurality of drums, each being rotatably supported within the water containing portion of the frame, each having a drum inlet for enabling goods to be washed to enter the drum and a drum outlet for enabling the goods to exit the drum, and at least some of the cells having drums therein;    d) a fresh water header for supplying water to the water containing portion of the housing;    e) a rinse water flow line that receives water that has been discharged from the water containing portion of the housing the rinse water flow line transmitting at lest some water back to the housing;    f) a treated water flow line that receives water that has been discharged from the water containing portion of the housing;    g) a separator for removing solid waste material from water flowing in at least one of the flow lines that receives water that has been discharged from the water containing portion of the housing and for transmitting such treated water to the treated water flow line; and    h) wherein water flowing in the treated water flow line supplies water to the wash zone;    i) a sensor that determines whether or not all or part of the rinse water is either discarded or transmitted to the reuse flow line.    
     
     
         24 . The continuous tunnel batch washer apparatus of  claim 23  wherein water flowing in the rinse water flow line supplies water to one of the wash zones.  
     
     
         25 . The continuous tunnel batch washer apparatus of  claim 23  wherein the water flowing in the treated water flow line is flowing a high flow rate that is higher than the flow rate of water flowing in the fresh water header.  
     
     
         26 . The continuous tunnel batch washer apparatus of  claim 23  wherein the water flowing in the treated water flow line is flowing a high flow rate that is higher than the flow rate of water flowing in the rinse flow line.  
     
     
         27 . The continuous tunnel batch washer apparatus of  claim 23  wherein the sensor is a turbidity meter that monitors the turbidity of water that has been discharged from the water containing portion of the housing.  
     
     
         28 . The continuous tunnel batch washer apparatus of  claim 23  further comprising a plurality of valves that meter the flow of water from the treated water and rinse water to the cells.  
     
     
         29 . The continuous tunnel batch washer apparatus of  claim 23  further comprising a plurality of valves that automatically meter the flow of water from the treated water and fresh water to the cells.  
     
     
         30 . The continuous tunnel batch washer apparatus of  claim 1  further comprising a plurality of valves that automatically meter the flow of water from the rinse water and fresh water to the cells.  
     
     
         31 . The continuous tunnel batch washer apparatus of  claim 23  wherein the separator is a centrifugal separator.  
     
     
         32 . The continuous tunnel batch washer apparatus of  claim 23  further comprising means for injecting ozone into the treated water flow line.  
     
     
         33 . A continuous tunnel batch washer apparatus, comprising: 
 a) an elongated outer housing having opposing ends, a hopper inlet at one of said ends and an outlet at the other of said ends, the housing having a water containing portion;    b) a plurality of lateral walls dividing at least a portion of the housing into a plurality of cells;    c) the housing containing a plurality of drums, each being rotatably supported within the water containing portion of the frame, each having a drum inlet for enabling goods to be washed to enter the drum and a drum outlet for enabling the goods to exit the drum, and at least some of the cells having drums therein;    d) at least a plurality of the drums having inclined chutes that transfer goods to be washed from one cell to another adjacent cell when the drums are rotated a selected angular amount;    e) a fresh water header for supplying water to the water containing portion of the housing;    f) a rinse water flow line that receives water that has been discharged from the water containing portion of the housing;    g) a treated water flow line that receives water that has been discharged from the water containing portion of the housing;    h) a separator for removing solid waste material from water flowing in at least one of the flow lines that receives water that has been discharged from the water containing portion of the housing and for transmitting such treated water to the treated water flow line;    i) wherein water flowing in the treated water flow line supplies water to the wash zone; and    j) a sensor that determines whether or not all or part of the rinse water is either discarded or transmitted to the reuse flow line.    
     
     
         34 . A continuous tunnel batch washer apparatus, comprising: 
 a) an elongated outer housing having opposing ends, an inlet at one of said ends and an outlet at the other of said ends, the housing having a water containing portion;    b) a plurality of lateral walls dividing at least a portion of the housing into a plurality of cells;    c) the housing containing a plurality of drums, each being rotatably supported within the water containing portion of the frame, each having a drum inlet for enabling goods to be washed to enter the drum, a drum outlet for enabling the goods to exit the drum, and at least some of the cells having drums therein, the housing having one or more water discharge outlets for enabling water to be discharged from the housing;    d) a fresh water header for supplying water to the water containing portion of the housing;    e) a tank that receives discharged water via an outlet;    f) a rinse water flow line that is receptive of water that has been discharged from the tank;    g) a treated water flow line that is receptive of water that has been discharged from the tank;    h) a separator that enables solid waste material to be removed from water flowing in treated water flow line;    i) wherein water flowing in the treated water flow line supplies at least part of the water to the wash zone; and    j) a sensor that determines whether or not all or part of the rinse water is either discarded or transmitted to the reuse flow line.    
     
     
         35 . The continuous tunnel batch washer apparatus of  claim 34  wherein water flowing in the rinse water flow line supplies water to the wash zone.  
     
     
         36 . The continuous tunnel batch washer apparatus of  claim 35  wherein the water flowing in the treated water flow line is flowing a much higher flow rate than the flow rate of water flowing in the fresh water header.  
     
     
         37 . The continuous tunnel batch washer apparatus of  claim 35  wherein the water flowing in the treated water flow line is flowing a much higher flow rate than the flow rate of water flowing in the rinse flow line.  
     
     
         38 . The continuous tunnel batch washer apparatus of  claim 35  wherein the sensor includes a turbidity meter for monitoring the turbidity of water that has been discharged from the water containing portion of the housing.  
     
     
         39 . The continuous tunnel batch washer apparatus of  claim 35  further comprising a plurality of valves that meter the flow of water from the treated water and rinse water to the cells.  
     
     
         40 . The continuous tunnel batch washer apparatus of  claim 35  further comprising a plurality of valves that automatically meter the flow of water from the treated water and fresh water to the cells.  
     
     
         41 . The continuous tunnel batch washer apparatus of  claim 35  further comprising a plurality of valves that meter the flow of water from the rinse water and fresh water to the cells.  
     
     
         42 . The continuous tunnel batch washer apparatus of  claim 34  wherein the means for removing solid waste includes a centrifugal separator.  
     
     
         43 . The continuous tunnel batch washer apparatus of  claim 35  further comprising means for injecting ozone into the treated water flow line.  
     
     
         44 . A continuous tunnel batch washer apparatus, comprising: 
 a) an elongated outer housing having opposing ends, a hopper inlet at one of said ends and an outlet at the other of said ends, the housing having a water containing portion;    b) a plurality of lateral walls dividing at least a portion of the housing into a plurality of cells, the cells being grouped into a first wash zone group of one or more cells, a second wash zone of one or more cells, a main rinse zone of one or more cells and a fine rinse zone of one or more cells;    c) the housing containing a plurality of drums, each being rotatably supported within the water containing portion of the frame, each having a drum inlet for enabling goods to be washed to enter the drum and a drum outlet for enabling the goods to exit the drum, and at least some of the cells having drums therein;    d) at least a plurality of the drums having inclined chutes that transfer goods to be washed from one cell to another adjacent cell when the drums are rotated a selected angular amount;    e) a fresh water header for supplying water to the water containing portion of the housing;    f) a rinse water flow line that receives water that has been discharged from the water containing portion of the housing;    g) a treated water flow line that receives water that has been discharged from the water containing portion of the housing;    h) means for removing solid waste material from water flowing in at least one of the flow lines that receives water that has been discharged from the water containing portion of the housing and for transmitting such treated water to the treated water flow line; and    i) wherein water flowing in the treated water flow line flows at a rate that is at least twice as high as the flow rate of one of the other flow lines.