Floor mat and particulate laden material washing apparatus and method

Abstract

A method of washing particulate laden material in a washer includes moving the particulate laden material from the intake of the washer to the discharge of the washer and through multiple modules or sectors. Liquid can be counter flowed in the washer interior along a flow path that is generally opposite the direction of travel of the particulate laden material. A specially configured recirculation/filtration arrangement removes a majority of particulate and organic matter from the washing fluid.

1 . A method of washing particulate laden material in a continuous batch tunnel washer, comprising the steps of:
 a) providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules including a first module that is next to the intake, and a volume of liquid;   b) moving the particulate laden material from the intake to the modules and then to the discharge in sequence;   c) adding a washing chemical to the volume of liquid;   d) after a selected time period, counter flowing a rinsing liquid along a flow path that is generally opposite the direction of travel of the material in step “b”;   f) recirculating a volume of liquid from one of the modules to the intake via a recirculation flow line; and   g) removing particulate matter from the volume of liquid flowing in the recirculation flow line with a filter after the volume of liquid leaves the first module and before the volume of liquid reaches the intake.   
     
     
         2 . The method of  claim 1  wherein in step “g” there is a pump in the recirculation flow line. 
     
     
         3 . The method of  claim 2  wherein the pump is in between the first module and the filter. 
     
     
         4 . The method of  claim 2  wherein the pump is in between the filter and the intake. 
     
     
         5 . The method of  claim 1  wherein the particulate matter includes sand. 
     
     
         6 . The method of  claim 1  wherein the filter removes particles from the volume of fluid via centrifugal action. 
     
     
         7 . A method of washing particulate laden material in a continuous batch tunnel washer, comprising the steps of:
 a) providing a continuous batch tunnel washer having an interior, an intake, a discharge, and a plurality of modules that segment the interior;   b) moving the particulate laden material from the intake to the discharge;   c) adding a washing chemical to the modules to wash the particulate laden material with a combination of water and said washing chemical;   d) after a selected time interval and after step “c”, counter flowing liquid in the washer interior along a flow path that is generally opposite the direction of travel of the particulate laden material in step “b” in order to effect a rinse of the particulate laden material; and   e) recirculating liquid from a first one of the modules to the intake via a recirculation flow line; and   f) removing particulate material from the recirculating liquid of step “e” with a filter.   
     
     
         8 . The method of  claim 7  further comprising boosting the flow rate in step “e” in the recirculation flow line with a pump. 
     
     
         9 . The method of  claim 7  wherein the filter filters sand as part of the particulate matter. 
     
     
         10 . The method of  claim 8  wherein the pump is in between the filter and the intake. 
     
     
         11 . The method of  claim 8  wherein the pump is in between the module and the filter. 
     
     
         12 . A particulate laden material washing apparatus comprising:
 a) a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules including at least an upstream, first module that is next to the intake and at least one downstream module next to the discharge, and a volume of liquid;   b) wherein the particulate laden material move from the intake to the modules and then to the discharge in sequence;   c) one or more counter flowing liquid flowlines that counterflow liquid along a flow path that is from a downstream module to an upstream module;   d) a recirculating liquid flow line connecting from the first module to the intake; and   e) a filter after the liquid leaves the first module and before the liquid reaches the intake.   
     
     
         13 . The washing apparatus of  claim 12  further comprising a pump in the recirculating liquid flow line. 
     
     
         14 . The washing apparatus of  claim 13  further comprising wherein the pump is in between the first module and the filter. 
     
     
         15 . The washing apparatus of  claim 13  wherein the pump is in between the filter and the intake. 
     
     
         16 . The washing apparatus of  claim 12  wherein the filter removes particulate matter that includes sand. 
     
     
         17 . The washing apparatus of  claim 12  wherein the filter removes particulate matter that includes organic waste material. 
     
     
         18 . The washing apparatus of  claim 12  wherein the filter removes particulate material using centrifugal force. 
     
     
         19 . The washing apparatus of  claim 12  wherein the filter continuously removes particulate matter from the recirculating liquid flow line as fluid flows in said recirculating liquid flow line. 
     
     
         20 . (canceled)